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The Grumman AA-5X Cheetah/Traveler/Tiger
Construction Process |
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 Fuselage Step 4: Balsa Uprights / Wedge Cut to size the 1/4" square balsa uprights that go between top and bottom longerons. Glue them in place. Refer to plans for locations.
From 1/4" balsa, make a "wedge" to fit into the tail end of the fuselage sides. |
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Fuselage Step 5: Bulkheads/Firewall Laminated There are duplicate 1/8" plywood pieces for F-1, F-2, Firewall, Firewall Doubler. These must be laminated together to make them 1/4" thick. Use epoxy or wood glue to laminate these pieces together. Be careful to keep them lined up exactly. |
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Fuselage Step 6: Bend Fuselage Sides Each fuselage side must have the top longeron cut to allow the sides to taper from the wing to the tail. Using a razor saw cut the top longeron 19 5/16" from the front of the side. Create another cut 1/16" back from the first one and remove the material to create a notch in the longeron.
Now take a scrap piece of wood that is 2.5" tall and place it on the table 13" back from the cut you made in the top longeron. Put the fuselage side on this piece of wood and push down on the fuselage side at the point where you cut the longeron. You will hear the fuselage side and longeron "crack". This is normal. You have now relieved the stress in the wood which will allow you to pull the tail end of the sides together when you join the sides.
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Fuselage Step 7: Fuselage Bulkheads Lay the right fuselage side on the table and pin it down. Epoxy F-1 to the fuselage side. Now glue the fuel tank tray into place. The fuel tank tray will help keep F-1 square in position while the epoxy cures.
Prop up the tail end of the fuselage side 5". Now glue F-2 to the fuselage side making sure to keep it square while the glue cures.
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Fuselage Step 8: Join Fuselage Sides It's now time to join the sides. Put some wax paper over the plans and place the fuselage sides over the top view with the top edge down. Use pins to hold the sides in the proper place. Pull the tail together and use some weights placed on the table to hold the tail end of the sides in place. Dry fit everything to make sure it lines up with the plans. Now glue the left fuselage side to the right side with the bulkheads and fuel tank tray. Use some tape to hold it together.
Glue the firewall double in place. Glue 3/8" balsa triangle to the sides and firewall doubler. |
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Fuselage Step 9: 1/4" Balsa
Cross Braces It's now time to glue the 1/4" square balsa cross braces to the bottom of the fuselage. Cut each piece and glue into position. Use white glue, epoxy or thick CA. Once the cross braces are installed, it's
time to sheet the bottom with 3/32" balsa.
From a scrap piece of 1/8" balsa, make 2 gussets as shown on the plans. These gussets are glued to the top longeron at F-2. They serve two purposes. To strengthen the longeron after being cut and to help position the turtledeck sheeting around the bend in the fuselage side.
Cut pieces for the bottom the 4"x36" 3/32" sheets. Notice that the bottom sheeting is cross-grain. Glue with CA or white glue.
Before putting the each next piece on cut some 1/2" wide scrap 3/32" balsa to make "scabs" to keep the pieces lined up and flat.
Continue sheeting the bottom but stop short 6 1/2" from the tail. The open area from there back will be covered with a hatch to allow access to the elevator control horn.
Make a wedge from 1/4" balsa that is 4 1/2" long and glue it in between the top longerons at the tail.
Cut a notch into this piece to allow the elevator control horn to pass through.
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