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20041125 - allegro - 02 - joinerbarslayup
20041125-allegro-02-joinerbarslayup: Following the Osborne walkthrough, I laid up the joiner bars on the bottom CF spars before laying up the whole panel. This helped in adjusting the whole fit a...
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20041125 - allegro - 01 - joinersflush
20041125-allegro-01-joinersflush: Here I have sanded the end of the joiner bar assembly flush with the plans. Also note I have one of the bars inside it's tube here. I had to do a little sanding on...
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20041124 - allegro - 09 - midsweepsand
20041124-allegro-09-midsweepsand: Here is how I sweep-sanded my webs. I placed the web on the plan, overhanging the rib line by the smallest of margins. Then, using a small 1" wide sanding block with...
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20041124 - allegro - 08 - dryfit2
20041124-allegro-08-dryfit2: Another shot of my dry-fit before sweep-sanding the webs. 20041124-allegro-08-dryfit2: Another shot of my dry-fit before sweep-sanding the webs.
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20041124 - allegro - 07 - dryfit
20041124-allegro-07-dryfit: To ensure I had the webs in the right order and everything, I did a quick dry-fit of the webs and ribs. Since I got this kit second-hand, I had to hand-cut two ribs that...
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20041124 - allegro - 06 - websganged
20041124-allegro-06-websganged: For the mid-panels, we'll be using webs #6-10, and there are a total of 4 a piece for each number. You'll be "ganging" two together to make the width of the spar. I...
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20041124 - allegro - 05 - sparcapsmisted
20041124-allegro-05-sparcapsmisted: There we go! Bottom spar caps in place. 20041124-allegro-05-sparcapsmisted: There we go! Bottom spar caps in place.
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20041124 - allegro - 04 - midbottomsparcap
20041124-allegro-04-midbottomsparcap: Hey, it's the Right Mid Bottom Cap! You need to LIGHTLY mist the bottom of the cap and adhere to the mylar. Again, stand DIRECTLY over the plans when doing so....
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20041124 - allegro - 03 - seeaccurate
20041124-allegro-03-seeaccurate: See! Accuracy is the key here. Lightly spray the bottoms of the mylars with 3M-77 and adhere to the plans. Stand DIRECTLY over top the plans when doing so, as to...
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20041124 - allegro - 02 - accuracy
20041124-allegro-02-accuracy: Next, I cut the tips of the mylar spar shims to the plans. I used a little masking tape to hold the mylar down, and again used a utility knife and many light cuts to cut...
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20041124 - allegro - 01 - cuttingmidmylars
20041124-allegro-01-cuttingmidmylars: To start the mid-panel build, we need to again cut mylar shims for the spar bottoms. Measure the width of the spar on the plans, and cut your mylars accordingly....
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20041123 - allegro - 08 - squeegeebar
20041123-allegro-08-squeegeebar: Using a piece of scrap ply, I tried to squeegee out the excess epoxy. It would be advisable to hold your (vinyl gloved) finger down on the fiberglass when doing this,...
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20041123 - allegro - 07 - glassingbar
20041123-allegro-07-glassingbar: I sprayed one side of each piece of fiberglass down with 3M-77 spray and then applied each to the underside of the joiner bar assembly, pressing down hard to ensure a...
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20041123 - allegro - 05 - sandingbarbottom
20041123-allegro-05-sandingbarbottom: Next, we need to apply the 5 strips of 2oz fiberglass to the bottom of the joiner bar assembly. Sand the bottom of the joiner bar assembly nice and FLAT. The FG...
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20041123 - allegro - 04 - castopper
20041123-allegro-04-castopper: Applying thin CA to the stopper bit. 20041123-allegro-04-castopper: Applying thin CA to the stopper bit.
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20041123 - allegro - 03 - makingstopper
20041123-allegro-03-makingstopper: To make the balsa "stoppers" in the ends of the tube, I slightly sharpened the rim of the piece of tube that stuck out, and gently cut out a disc of 1/8" balsa. Then...
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20041123 - allegro - 02 - joinertubesanded
20041123-allegro-02-joinertubesanded: After trimming sanding, they don't look so bad! They weigh 14g total, and that is before the massing "hacking" that will occur on the ply sides to make them align...
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20041123 - allegro - 01 - joinertubecured
20041123-allegro-01-joinertubecured: After curing, this is what my joiner tubes looked like. I would have taken more care in cutting those 1/64" ply wedges to size when I was doing the lay-up, but my...
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20041122 - allegro - 10 - tubeswithepoxy
20041122-allegro-10-tubeswithepoxy: The same with the tubes. You will need to cut the 1/64" ply sides into "wedges" to have the sides be flush-fit. After the 1/64" thick ply sides, you'll need to then...
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20041122 - allegro - 09 - barwithepoxy
20041122-allegro-09-barwithepoxy: After you've got everything square, fill in the gaps with the epoxy slurry, and apply the 1/64" plywood sides. 20041122-allegro-09-barwithepoxy: After you've got...
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