Left: Foam block measured, marked, ready for initial hot wire cutting.
Right: These are the wing Jigs bondo'd to the floor...ready for foam cores.
Left: This was the 4' hot wire cutter..we also used a home-made 6' cutter for the large pieces.
Right: Piece of the trailing edge foam core complete.
Left: Here is a shot of the above piece prior to cutting. Note the wing template attached to the foam material.
Right: Pic of the interior aileron template prior to cutting of the aileron torque tube hole. That square cut-out section is later glued back in after the interior of the future aileron is cut out.
Left: Checking the cores prior to placing in the wing jig.
Right: Trailing edge foam cores mounted into the wig jig waiting for cap spar lay-up.
Left: Using a dremel with router blade to dig out areas for the hard points.
Right: This shows the lay-ups on the wing bolt access channels.
Left: Bolt access channels complete with hard points and sheet alum. covers. Ready for spar cap layup.
Right: Pic shows the initial layers of the spar cap glass lay-up into position.
Left: Spar cap complete and peel ply covering.
Right: Leading edge foam cores micro'd into position on top of the spar cap.
Left: All wing foam in the jig and curing.
Right: The jig is then taken off the floor and layed onto the work table for next layups.
Above: The bottom halves of the jig are bondo'd to the work tabe and the othe halves are removed for the next wing spar layups.
Left: Unidirectional glass is layed into the channel for the upper and lower wing spar layups.
Right: Then the wing in covered in bi-directional glass lay-ups.
Left: Pic of one wing completely glassed on both sides awaiting the final aileron cutting.
Right: Cutting out the aileron with a dremel and my home-made angle cutting tool.
Left: Shows the installation of the aileron hinges.
Right: One aileron cut out complete.
Left: Both wings complete (except for winglets) awaiting the final aileron installation.
Right: Aileron installed on one wing.
Left: Aircraft leveled and both wings in position for initial mounting procedures.
Right: This is a pic showing how the ERacer push-pull aileron control cables hook into the aileron bell crank and control the ailerons on this aircraft.
Left: Winglet template attached to foam prior to hotwire.
Right: First winglet foam core cut out and pieces glued together.
Left: Glass lay-ups on one side of the winglet.
Right: This is a completed winglet with the bottom edge cut for attachment and rudder line marked prior to cutting.
Left: Winglet bondo'd into correct position with a wood temporary support.
Right: Winglet attach point...ready to begin series of attachment layups.
Left: First attachment lay-ups on interior edges.
Right: Next layers of glass laid and peel-ply'd.
Left: Pic of interior lay-ups after cure...ready for next steps.
Right: Positioning the foam for next surface addition.
Left: Foam is micro'd in and shaped.
Right: Pic shows outer structural lay-ups attaching the winglet to the wing.
Left: Now more foam is micro'd into position for further shaping.
Right: Foam is carved into final wing shape.
Above: Final lay-ups are made to the outside of the winglet.
Left: Pic shows the rudder hinges, rivets, screws, hooks and return springs needed for rudder completion.
Right: Rudders are cut out and aluminum rudder horns are installed at the base of each.
Left: Shows the inboard structural lay-ups needed for winglet attachment to the wing.
Right: Rudder installed on winglet.