Laser Cut Telemaster Build Helps, Hints and addendum's

[asnowman]

Hello all,
I will be beginning the build of laser cut Senior Telemaster from Hobby-Lobby.
To help others and to avoid building mishaps, I will be posting helps tips and addendum's to the plans that are shipped with the kit. (others can learn from my mistakes).
I will post pictures and impressions of the process. As an experienced builder I plan to take on this build as a novice to check the overall instructions.
All questions are welcomed and I will do my best to help anyone.
Because this is a build, I intend to take my time and check every step. Not going for speed here.

[asnowman]

Which Telemaster are you building? The 40 size or Senior Telemaster. Thanks

Sorry rodsmith123, You are correct, there is more than one.... I will be building the Senior Telemaster. I have also read your posts and will be incorperating some of your modifications.

Changed the title to reflect the changes.

[asnowman]

Step 14 correction.
Loose fit all ribs into there appropriate notches
in LEP. Assure that all ribs are bottomed in their
respective notches before applying glue.
At this point make sure that WBS is placed between
W5 and W6 before gluing these ribs in place,
then use thin CA to glue ribs in and
use the Building Square to insure that each rib
is at 90° to the bench. Glue them at LEP, the bottom
spar and TEP. Ribs W2 and W3 will also be
glued to BSA. NOTE: Ribs W2 through W6
must be in their correct locations or you will
not be able to insert the wing bar later. They
look very similar however the butterfly opening
is cut to accommodate the dihedral angle
and will not line up if out of sequence.

All steps up to this point are well written and illustrated. The online videos are a real help as well.

[asnowman]

Step 16 Correction
Plane or sand a slight bevel on the bottom of the wing tip (WT)
to increase glue land. Use the 45° gusset (WTG) to get the correct
angle on it and glue it at the leading and trailing edge as well as
the gusset. Align the gusset on center with the spar. Glue in a 1”
piece of 1” triangle stock at the leading edge and a 1” piece of
¾” triangle stock at the trailing edge. Cut and glue pieces of 3/8”
triangle stock (1/4" Stock supplied in the kit) to W14 and WT
between the leading edge and the
gusset and between the gusset and the trailing edge. Use a razor
plane to plane the leading edge and trailing edge triangle stock
filler pieces to contour with W15 and WT. Use a straight edge
across the top of W14 and W15 to help align the top of WT.
Place the top spar in position in the notches
provided and mark the location of the W1
assembly. Trim the spar off at this line then
place the spar in position and use aliphatic
resin to glue in the top spar. Weight it to assure
it remains bottomed in the rib notches
until cured.

This is correct with the picture that applies to this step. I had some 3/8" triangle stock on hand and used that instead.

[asnowman]

I am happy to find that all the parts of the wing fit very well.
If they are built in reference to the plans, the wing will be perfectly straight and true.
Also, I have used the Blue Tape Method to shape the leading and trailing edge.
This allows the surfaces to be sanded and lets you know when to stop sanding, protecting the ribs from over sanding.
(Thanks to all the builders that shared this very nice tip)

I have also found that the leading edge sheeting was not as wide as the plans called for.
Also, my local hobby shop did not have any balsa that was 48" long.
If you find yourself in this situation you can edge glue the 3/32"x4"x48" piece with the larger left over edge of sheet 36 and use 38 for the other wing. Be sure to square up the sheets before you begin to sheet the wing.

[Colorado kid]

asnowman,

I have used the Blue Tape Method to shape the leading and trailing edge.


Could you please explain what the Blue Tape method is for your leading and trailing edge treatment. A novice would not have an idea why or how it is used to shape.

Thanks,

I think your explainations are very good and are helping those build without mistakes, keep up the good work

CK

[asnowman]

The blue tape method that I use is to cover the ribs or any adjoining surface with blue masking tape. Ordinary masking tape will work, but the blue tape is easier to see when you have begun to sand the tape.

Apply tape to all of the ribs where they meet the trailing edge and the leading edges, a small piece with suffice.
The tape will allow you to sand the adjoining surface while protecting the rib from being sanded, just make sure that you don't sand through the surface of the tape. If you begin to sand through you are at the correct height to blend the two surfaces together. The most clear sign is that there will be blue powder in the dust.
This allows for more control and protects the ribs from being sanded. Because of the cutting accuracy of the ribs they need to be protected so that you don't change the airfoil of the wing. After you finish sanding you can remove all of the pieces of tape and viola.

The leading edge of the Senior Telemaster Laser Cut Kit has to be sanded down quite a bit, checking the progress with a straight edged often will ensure better success. The trailing edge requires very little sanding, but the blue tape should still be used to protect the ribs.

You can see in the pictures that a straight edge is used to keep the profile of the ribs that should match the leading edge. Note the difference between the unfinished edge and the finished edge. Use this same method for the trailing edge.

[asnowman]

Note that the sheer webbing does not touch each rib and should be centered between the ribs. Make sure that the top of the sheer webbing is level to the top of each rib before gluing down.

Step 20.
Install and glue 3/32” sheer webs (WSW) to the front
of the spars, make sure that the sheer webs
are flush with the top of the ribs. Between W3
and W4 use SW-W4, Between W2
and W3 use SW-W4 this sheer web must also
be flush with the tops of the ribs.
Also, the web between W3 and W4 must be trimmed to
allow it to fit around the BSA. This will
provide a ledge for installing the leading edge
sheeting later.

[asnowman]

23
Install and glue the trailing edge anti crush
webbing between TEP and the top sheeting.
The top sheeting is made from one of the 3/32"x4"x48"
sheets that is cut into 2"X48"strips.
Recess the webbing as required until it contacts
both the top and bottom sheeting and
then glue it in place.

[asnowman]

29
The leading edge sheeting is supplied as twp (not sure what this was)????
4” and one 3” 3/32” x 48” sheets. These must (No 3" sheets in the kit)
be edge glued and then two 4-1/4” sheets cut
from this assembly. Butt the straight edge of
this sheet up against the top spar and use a
piece of masking tape at each rib to hold it
firmly against the spar. Using the tape as a
hinge, swing the sheet back and apply a bead
of aliphatic resin glue to the top spar and then
bring the sheeting back down in to position.
Let this glue cure before proceeding.

This step was included because twp is not marked as such, I could not find it.
If it is the 3/32"x4",48" sheet, the instructions are not clear on this.
Refer to the other wing assembly post #6 for a fix that you can apply.