SZD-10 bis CZAPLA ASSEMBLY MANUAL IN PICTURES

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SZD-10 bis CZAPLA ASSEMBLY MANUAL IN PICTURES

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RUDDER Plan and parts:

SZD-10 bis CZAPLA ASSEMBLY MANUAL IN PICTURES

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Assembly steps:

Photo above: glue together rudder spar, ribs and trailing edge. Clamp spar to a flat surface (chipboard on the photo) and make sure the straight aligment of the trailing edge. Trailing edge is a sandwich made from inner plywood and outer balsa. Balsa is later sanded to triangular cross section (se sectional drawing on the plans). Cover the rudder structure with 1,5 mm thick balsa sheetings. Take care not to warp the rudder. If triangular piece of sheetings breaks along the grain, just glue it back. It is not structural, but a scale detail.

Photo above: sand complete rudder with fine sandpaper to smooth the surface and joints. Make sharp outer edges slightly rounded.

SZD-10 bis CZAPLA ASSEMBLY MANUAL IN PICTURES

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HORIZONTAL TAIL Plan and parts:

SZD-10 bis CZAPLA ASSEMBLY MANUAL IN PICTURES

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Assembly steps:

Photo above: Prepare all parts for the horizontal tail assembly. Parts are 3mm lite plywood, 1.5 and 3mm balsa and 3x3mm spruce strip. Note the elevator trailing edge! Trim tab only on the left elevator!

ELEVATOR

Photo above: "clamp" all elevator ribs between upper and lower spar halves. Glue them all together. Install and glue thin plywood elevator trailing edge.

SZD-10 bis CZAPLA ASSEMBLY MANUAL IN PICTURES

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Photo above: glue spruce strip at the leading edge of the elevator. Glue leading edge sheeting over the spar, ribs and spruce strip. See plans for details and proper procedure. Note! Dont warp the elevator!

Photo above: cover trailing edge with balsa doubler both side! (Note! Trimtab only on the left elevator!)

STABILIZER

Photo above: glue leading edge balsa to form "T" shape. Glue spar, ribs and "T" leading edge. Dont warp the spabilizator structure. Note: "Peg" at the root rib is facing toward ground and it serves for attaching elevator onto the fuselage with a bolt M3. It is optional. Also the root rib is mounted at angle as horizontal tail has "V" dihedral. See plans for details.

Photo above: install press nut for the stabilizator strut. It is on the bottom side of the tail. Install and glue (5 min epoxy) joiner bushnings made from 5/4mm aluminum tube or just rolled aluminum sheet (canned drink).

SZD-10 bis CZAPLA ASSEMBLY MANUAL IN PICTURES

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Photo above: install tip bow. Use scrap balsa to fill space at the main spar. Sand to triangle. See detail on the plans. Glue balsa blocks at hinge attachment points.

Photo above: prepare the 1,5mm thick balsa sheeting. Draw a strong line over the inner side of the balsa where a "kink" will be made at the tip over the last rib. Left stabilizator sheeted, right unfinished. Note sanded leading edge. See plans for the detail.

Photo above: both horizontal tail parts sanded. Bottom side up. Note attachment pegs and press nuts for the struts. When both stabilizers are shetted and leading edge rounded per plans, sand smoothly entire tail with a fine sandpaper. Cut openings on the elevator trailin edge at hinge locations, and glue hinges in.

SZD-10 bis CZAPLA ASSEMBLY MANUAL IN PICTURES

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FUSELAGE Plan and parts:

Assembly steps:

Photo above: Prepare all fuselage parts and identify them per plans. Ttry to assemble parts without gluing, to check the parts fit and to asure proper aligment by sanding off some edges where necessarry. Only then you can glue parts together. Note: test fit can be done front and aft part separately.

SZD-10 bis CZAPLA ASSEMBLY MANUAL IN PICTURES

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Photo above: there are some "tricky" details on the fuselage, especially at the curved lines. To avoid breaking the curved parts, soak them in a hoat water and bend them properly when soaked. Glue when dry and sand missaligments away. Make proper splice joints at spruce longerons.

Photo above: Install wing strut attachment bracket before the sheeting of the fuselage because of easier access. Assemble fuselage on the board. Make an extension, as the landing gear assembly is lower than bottom of the fuselage. Check for straightiness and simerty.

Photo above: Test servomotor installation, route the bowdens for the tail surfaces trough holes in the fuselage formers and glue them at these former crossings. Dont use CA glue! It will make bowdens brittle! Use 5 min epoxy instead! Left bowdens longer than needed. You will trim them later.

SZD-10 bis CZAPLA ASSEMBLY MANUAL IN PICTURES

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Photo above: cover the fuselage with 3mm balsa sheets, nose and fuselage sides only. Use couple of balsa plates to form the nose of the model. Make a tunnel at its bottom side for the towing hook. Sand smooth to the fuselage contour. Make simple tow hook with static "U" and movable straight wire of 2mm diameter.

Photo above: solid balsa for transition between sharp and rounded part of the upper fuselage. Use some scrap balsa to assist sheeting around the wing joiners. Glue wing joiner tubing firmly in the fuselage structure. Use plenty of epoxy glue! You will trim tubink to length later at wing assembly stage.

Photo above: glue solid balsa at transition from triangle to oval turtledeck, sand and apply upper fuselage balsa sheeting. Sand transitions smooth. Check cross sections on the plans. Cover the fuselage bottom with balsa sheeting.

SZD-10 bis CZAPLA ASSEMBLY MANUAL IN PICTURES

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Photo above: Sheeting of the transition from fuselage to the vertical stabilizer is somehow "tricky". Use smaller pieces of balsa and orient the grain to assist easier bending. Sand smoth. Use balsa filler to hide gaps or mistakes. Note: when aligning horizontal tail joiners, use help of hor. stabilizer itself. Keep them on the joiners until glue permanently attach them into the fuselage structure. Use plenty of epoxy glue. Cut bowden tubing flush at the fuselage covering stage later in the assembly.

Photo above: make a template to form a landing skid. Glue several layers of thin ply, clamp between templates and let to dry. It is not a bad idea to insert glass fabric between layers for better strength. Use epoxy! Use folded paper towel to evenly spread the pressure.

Photo above: for scale detail, make hardware from aluminum sheet. Nose hook and bracket at rear.

SZD-10 bis CZAPLA ASSEMBLY MANUAL IN PICTURES

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Photo above: install two rubber tubing shock absorbers between the landing skid and bottom fuselage. Use small brackets made from aluminum sheet. Screw together. It is not a bad idea to use long screws and hardwood doublers inside the fuselage bottom sheet. Carve a tail skid from hardwood. Make a rubber tube shock absorber and aluminum brackets. Screw to the fuselage at its rear bottom end.

Photo above: make canopy frame from wooden frame and bented aluminum bar (3mm diameter). Join aluminum bars using CA glue and thin sewing thread. Soak joints and thread well and let to dry. Use clear plastic sheet and flat wrap over the frame. No need for vacuum molding the canopy! Use glue from inside corners of the frame. At the model covering stage, use self adhesive colored tape, to imitate outer frame of the canopy cover. Use photographs and canopy plan for the reference. Use magnets or rubber band inside the canopy and cockpit to install canopy on the model. You can even use tiny hinges if you prefer.

SZD-10 bis CZAPLA ASSEMBLY MANUAL IN PICTURES

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WING Plan and parts:

Assembly steps: Glue wing plan on a straight and leveled wooden assembly board. Cover paper plans with clear plastic wrap to prevent glue to stick parts to the plans.

Photo above: Lay parts over the plan and asure proper aligment. Be careful not to break tongues on the spars that keep proper wing twist. If broke, use a doubler to fix it. You will sand dtem away later in the process.

SZD-10 bis CZAPLA ASSEMBLY MANUAL IN PICTURES

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Photo above: slide the shear web onto the ribs. Note a tounge at bottom of the web mentioned earlier.

Photo above: there a spar caps from spruce wood goes. They should be glued both to the ribs and a web. White carpenter glue recomended.

Photo above: diagonal spar, both upper and bottom side needed. Note wing joiner tube installed. Prepare aileron servo bay and check the servo to fit.

SZD-10 bis CZAPLA ASSEMBLY MANUAL IN PICTURES

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Photo above: air brake servo tray. Adjust opening to suit your servo. Wing strut mounting bracket installed and its plywood reinforcing plates.

Photo above: sheeted wing. All sheeting, balsa 2mm. Note solid balsa strip at leading edge. Use templates for checking the leading edge contour.

Photo above: make and use 3 wooden "craddles" to assure proper wing twist while sheeting the lower wing surface. It is almost impossible to correct wrong wing twist, after the wing is sheeted with a balsa sheeting.

SZD-10 bis CZAPLA ASSEMBLY MANUAL IN PICTURES

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Photo above: trim wing root sheeting to fit fuselage and glue plywood strip on the inside root sheeting. Trim to fit again. Set proper length of the wing strut tubing. Check simetry of the model and equal dihedral of the wing. Glue at proper length, drill trough a tube and fork and rivet them together. Use soft steel rod as a rivet (piece of a 3mm dia nail) as wing struts are functional and carry wing loads! Use balsa to form streamlined strut fairing. Use plans for reference. Assemble the ailerons and make them proper twist. Use same technique as for rudder and elevator. Assemble the airbrakes. Test them for proper movements before covering the wing. If some colisions are present between moving and static parts of the airbrakes and their slot, carve slot away for clearance. Cover model using scale red and black covering, or go wild as I did on my prototype!