Estes Space Shuttle Columbia Build #1385, Part 9, Rudder Fitting

After the glue fill there was still a dip where the glue had shrunk in.

Some CWF filler was applied then sanded with 400 grit. 

The tube marking guide matched up! The tube is marked on two sides.

The tri-fold Shock Cord Mount is printed inside the marking guide. This old style mount is printed on 65 lb. cardstock, stronger than the usually printing the mount on 20 lb. instruction sheets.

The rudder drag brake still a tight fit in the balsa rudder.

The top and bottom of the rudder cut out was trimmed.

Again, I used very little glue to set the cardstock drag brake.

After the initial tack glue had dried I checked the alignment. It did need some adjustment. 

Glue fillets were applied and tape held the cardstock triangle under tension - pressing and centering the brake in the correct position.

Estes Space Shuttle Columbia Build #1385, Part 8, Cutting & Setting The Flap

The instructions have you glue the wing onto the tube before cutting the wing flap. I thought it would be easier to make this cut with the wing not glued on yet.

I would assume the single flap on the right side of the wing makes a slow stabilizing spin during boost. It reminds me of the spin tabs on the old Astron Space Plane.

You use a template to trace and cut the elevon flap.

The vertical cut was cut all the way through the balsa. 

I tried to make the horizontal cut not quite through the wood hoping to make a "hinge". When I tried to bend the half cut - the elevon flap broke through! No big deal. I'll just glue it as it was intended.

I used very little glue on this joint.

A little glue allows for repositioning. You can always add more glue after you get the right angle.

Check the angle with the supplied guide. 

After the angle was right - 

Small bits of glue were added to the bottom open joint and the angle checked again.

More glue was added to fill the gap.
 

Estes Super Orbital Transport Build, Kit #7314, Part 10, Gluing Elevons

The glider elevons (Part FF) have an angle sanded on the gluing edge.

Use a 220 grit sanding block while checking the angle with Part GG.

Here's a glued on elevon.

The edge fit is good but is tough to get perfect.

Any open joint seams are filled with CWF and sanded with a 400 grit block.

Semroc MMX Orbital Transport, KMX-01, Build Part 8, Orbiter Glider Construction

The dihedral of the glider wing is done by setting the joint over the glider body tube. When the outside tips of the wing sides touch your work bench, the angle is correct.

I also filled the joint at the wing center.

The instructions suggest glue fillets along the top joint of the wings.
I wouldn't recommend this - it isn't needed. Getting a bubble free fillet is difficult and adds a lot of weight.






One side of the template jig is used to set the elevon angle.







The notched hook is glued even with the front of the wing.
GOTCHA: Notice anything wrong here? More in the next post.

Apogee SR-72 Darkbird Build Part 7, Elevon Hinge

The elevon hinge is a fibrous, almost transparent piece of cloth. I've seen this material before but can't recall where.

The instructions say to use CA glue but I was concerned that would make it stiff and possibly crack later on.
Because it is so porous, I knew white glue would work. I applied the glue and spread it out evenly with a Q-tip. I glued half onto the elevon first.

The other side of the hinge is centered on the back edge of the wing.

The picture on the left also shows the elevon stop pieces, the forward ones are glued in place.






I used the dihedral guide piece to find the correct start angle and set the rear stop piece.

The top picture shows the small orthodontic rubber bands hooked over the outside ends of the elevon stop pieces.
This picture has the pop-pod engine mount in place. The stop wing is holding the elevons flat, even with the surface of the wing.

In the lower picture the engine mount and stop ring are slid out the back. The rubber bands have raised the elevons.

Estes Orbital Transport, Kit #K-42, Part 14, Glider Assembly

The wing is glued onto the glider BT-20 tube.

TIP: Don't even try to make a glue fillet in the tight wing joint. It would take too many bubbled glue fills adding weight to the glider.
I did add a fillet to the front and rear of the wing - not down the sides.

The glue side of the elevon was also sanded at an angle for a better joint. This make for a better fit and a stronger model.








The original kit guide was used to set the elevon angle.

The glider nozzle was made a double layer nesting "super shroud" for strength.
Here I'm cutting off the overlap of the inside shroud.

Here's the thicker nozzle glued onto the laminated rear disk.