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Date:  5-28-2015
Number of Hours:  1.70
Manual Reference:  Step 6
Brief Description:  Preparing for Canard upper spar cap

Removed tape from Canard shear web and surrounds, cleaning up edges with wood chisel and sand paper, and sanding micro bumps smooth.

Foam plug in hardpoint hole did not work well. Made one hardpoint from it, but wasn't confident it didn't leave voids at the bottom where I can't see. Occured to me I could SEE the bottom if I cut the plug I made in half. This worked well, but just shows it doesn't reach the bottom. Try making a cardboard template from the plug and this works perfectly. Place the resulting template over drawing M-11 and it matched perfectly. Decide I am an idiot, because I could have made a template from M-11 and avoided a lot of mucking about!!!

If I did this again would do the following:

1. Make a cardboard template of the H100 hardpoint as shown in drawing M-11.

2. Place your F-jig on M-11 and mark where the hardpoint is placed on the chord line.

3. Measure B.L.15.6 from the centerline, this is the centre of the inner hinge. Mark the other hinge center points as per CH10 fig 48.

4. insert CZNC-12A into the elevator tubes, line up the hinge point in CZNC-12A with the B.L. 15.6 mark, and check the placement of the hinges with the tubing cutouts. Adjust your hinge placements to suit.

5. Cut holes in foam for the hardpoints with hacksaw blade sharpened to a point. Check as you go with the cardboard template, and clean out with a wood chisel.

6. Cut H100 hardpoints to the cardboard template, I used an electric coping saw. Then put a woodscrew in the top so you can try it in the holes and pull it out again, then do so, adjusting if neccessary, and sanding the upper surface flush. I went a bit under.

7. Butter the hardpoint and hole with micro and squooge it in, holding it in position with a couple of nails
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Holes prepared, cutting hardpoint foam

Holes prepared, cutting hardpoint foam

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Foam all trimmed

Foam all trimmed

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Squooging in micro

Squooging in micro

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