RC Aircraft Fabrication

Wing fabrication:
1. After cutting the sheet by using the hot wire cutting system, we will get the wing but we
need to do some finishing. Use sand paper to give a smooth finish to the wing.

This shape we should get after the sanding work

2. Now mark a center line on the wing and draw the dimensions on the top of the wing as shown in
the figure below.

Center line

5cm

4cm 7cm
3. Now cut out the aileron section and you will get the new shape as shown in the figure.

Wing shape after cutting

Space for the ailerons

4. After cutting the aileron section in the wing, draw a center line on the edges as shown in the
figure this will help to fixing the ailerons.

Mark the center lines on edges

like that
5. Now use coroplast sheet and cut two piece for the ailerons as shown in the figure.

Ailerons

5cm

These sheets will fit into the aileron section and act as ailerons. Please make sure they
are of the same size as the slot and fix them symmetrically. Any asymmetry here will
cause your aircraft to roll.

6. Make a slot on the wing to fix the rod at a distance of 1cm from the leading edge as shown in
the figure.

Slot to place the wing holder rod

Leading edge
4 cm

Trailing edge
Space for the ailerons

7. Measure the length of the aluminium pipe, mark it’s mid – point. Place the aluminium
rod coinciding the center line on the wing and draw the outline as shown in the figure
below
8. Now remove the material of the outline of the rod using sand paper upto 60% depth
w.r.t the diameter of the aluminium rod as shown in the figure below.
 Fix wing rod using cello tape as shown in the figure above.

9. Make a slot on the wing as shown to place to place the servo. This slot should be according
to dimension of servo and must be on the center line as shown in the figure below.

Slot for the servo

1.0 cm
10. Now take the wing and make the holes as shown in the figure below.

Now insert the servo in the slot as shown in the figure below.
Using Zip ties fix the servo to the wing.

11. Now fix the ailerons as shown in the figure below using cello tape.

Fix Ailerons using

Final wing with servo motor, wing holder rod and ailerons attached
cello tape
Fuselage Fabrication:
1. Make a drawing for fuselage on the coroplast sheet as shown in figure, put correct values of
every dimension. It is very important to cut it correctly.

How to use Coro?

 Fuselage is fabricated using corrugated plastic it is also called as coroplast.
 The Lines visible on the Coro sheet is horizontal lines
 If you take the cross section of the Coro sheet you will be able to see square boxes in a
row.
 Always mark the sketch before cutting the Coro.
 When you cut the Coro sheet horizontally, cut outside the marking. When you cut
vertically or slanting line keep a scale and cut over it.
 The part between the line is called flute, i.e. if there are four horizontal lines then there
are three flutes.
How to use Cutters with Blade?
Remove the projected part Single flute cut in folding part of
fuselage

Making a knife impression on bending part using blunt

side

After cutting sheet will get this shape

Cut & remove first layer of the sheet

2. Now after cutting the sheet we have to fold it as shown in the figure below.
3. After folding the sheet hold it at the 900 and apply the hot glue on the edges. If having any
problem ask trainer how to fix it.

Fix wing holder as shown in fig

Completed fuselage
4. Now again draw design for the horizontal tail and vertical tail section you will get the shape
as shown in the figure.

Horizontal tail Vertical tail

Center line

5. Now mark a center line on the horizontal tail as shown in figure above and match line and
vertical tail then fix it as shown in the figure by using hot glue.
 Rudder

Elevator

Angle 900

6. Make a center line on the tails as shown in the figure and fix control horn as shown in the
figure below.

Make line as shown for fixing horns

7. Now take the fuselage and fix complete tail on end as shown in the figure.

Fix tail on the fuselage as shown by using glue

8. After fixing the tail now we have to fix the wing holder which should be place like
that as shown in the figure.
 Fix the wing holders as shown

9. For next step approach to trainer for fixing the servo motor in the fuselage section.