Another T45 Swallow - Slingsby --

[MarnochS]

Yet another PGD Slingsby T45 Swallow

Major construction pretty much finished inside of 2 months ( a record for me ) in my attempt to have two airplanes at the painting stage.
Some photos at the different stages
Using 3/4" x 1/4" UHMW Polyethylene strip ( and skid plate ) similar to Dean Gradwell's Cherokee II ( and Gene's 1/3 Cherokee II)



Digital gauge was helpful to jig the wing up when applying the lower sheeting ( trying to avoid any twist ) Thanks to John Ellias for finding the TL90
CA used when applying the cap strips and sanding bars to keep things level



Test fitting all the pieces for inspection and a test panel using Polyfiber process but PPG Omni LV for the Yellow so it will match .



1/8" Great Planes clear pin hinges for the ailerons and some artistic license in the wing tips - I really liked the Horton upswept tips on Dean's full-sized Cherokee so...... a 3"x1"x12" block of balsa and time with 80 grit sandpaper was required.



90% done so that means only 90% left to do......

Scott

[ARUP]

Nice! I see you have an inspector, too!

[DennisB]

Nice Scott, looking forward to seeing it at Visalia. I was very close to buying one of these kits but I have a backlong of projects.

[Pgoldsmith]

Nice Scott, there should be several at the Monticello Aerotow, look forward to seeing it in person.

[MarnochS]

Thanks Guys, ......more progress.

My version of the canopy release ( accessed via the top hatch as I didn't want anything on the outside )



Wing tip skids using 4-40 pushrod material and 1/8 brass tubing ( leftover from all the fuel tanks I've used ) and the drill jig ( copied from Gene's Cherokee II build ). Friction holds them in place.
I'll probably solder a washer to the posts to prevent them from driving through in the event of a less than graceful landing.
For aileron spacing, I had to add another wing tip rib ( 1/8 lite-ply and 1/64 ply ) then I replaced the original wing tip rib with a 6-ply 1/8' rib to glue the Balsa to.





Successfully coaxed the 1/64 plywood around the leading edge of the center section.. using a fair bit of water spray and the hot iron/glue technique.
Magnets on the hatch access are my "removal tool" for getting the hatch off. Four small 4mm x 2mm magnets around the corners of the hatch hold it in place.

Checking on the look of the wing tips with the ailerons installed

[Swiss1]

Looking good Scott!

[ARUP]

When all of the models appear at Horizon we'll have to dub them 'The Swallows of Monticello'!

[MarnochS]

........"When the Swallows come Home".....

[MarnochS]

Pre bent the canopy faring plywood before installation as it was flatting out on the narrow section at the back... Quart size paint can is the perfect form.



Matching the wings to the fuselage with some minor error corrections as I built the root rib straight instead of at an angle ( to match the taper of the fuselage ).

[JimD]

Thanks for the inspiration Scott...particularly that last little part! 😉

[MarnochS]

Sand, Sand,....Sand,....and more sanding....
and a Sailplane emerges......




And then...on to .... ..."Sculpting with Sandpaper"........ had to add some "extra" thickness to mine.... so I could sand ......oops.....Sculpt it to shape....
Used a ).010 shim in-between the base and fin to allow for removal ----- I hope......
the self-adhesive sand paper (150 grit ) attached to a popsicle stick worked great.

[lenb]

Geez Scot, you're closing in on it now, Looks like your just about ready to start covering it,

[MarnochS]

Hi Len,

Actually that has already started, Wing tips , Stabilizer and Fin / Fin base are glassed/epoxy ( 0.5 oz glass ).
Figured if I glassed the Fin first there would be a slight safety margin while "shaping" the fin base........



The plan is to start covering this weekend with Stits lite ........after a little final SANDING............

[lenb]

Thats great,
I would LOVE to cover and paint versus the plastic covering. Believe me!!

[MarnochS]

A little better detail of the bely/nose skid using the UHM material and stainless steel skid....
Socket head screws will be replaced with countersunk units.



had to put the wings on to match sand the underside of the wings and check the look of the rounded boom section and of course the new nose.

[Gene C]

Looks outstanding.

[MarnochS]

A productive Saturday ......temperatures were in the 80's which is a help for Epoxy cure time. ( 0.73 oz .glass )






And fuselage transport jig in an effort to reduce Hanger Rash.

[ARUP]

You gonna bring it to Horizon?

[MarnochS]

Hi Mike......that is the Plan.....