The Double Eagle Specifications Weight ...................385 pounds (dry) BICINE eaceseyesnenune- 1005 -" Wing Span 2813” Gross Weight... 00 pounds Wing Cord .. 55 inches Useful Load 5 pounds Wing Area -. 127 Sq ft Wing is sire: Fuselage ................ 18 feet ‘The Fower is the Reliable V.W. 4-Cylinder Engine of 1835ce approx. 6G i1P For Plans, Videos, and Propellor Hubs, contact L.E. Milholland P.O. Box 747, Brookshire, Texas 77423 281-375-5453 * email: leonard@[Link] 2 Web: [Link] For Kits and Material Packages, Welded Fuselages, “contact John Bolding” Baytown, Texas at 281-383-0113. Cost To Build Estimated at $5,000 to $7,500 depending on your scrounging ability.Double Eagle Material List Steel Tubing. (4130) 6° 11/87x.120 ~ 6 1°x035 VY 7/8*%.035 2 7/8"x.065 127° 3/4°x.035 - 8 .-3/4".049 31» 3/4°x.065 14 5/8°x.049 93" 5/8"x,035 1 yp2R.049 al 3/8"x.035 2 2/8'x.065 Steel Sheet (4130) 18°x36" x125 = 18"x18" x.063 18°x72"x,025 (tail ribs) ~ Aluminum sheet (6061-6) 487x36"x.016 12°18" 125 Aluminum Tubing 12 1/4od x12 3003-0 (pitot tube) 8 1" streamlined (jury struts)w/ installation kit 2ea, 3°x8" streamlined struts 2ea, 2*x8" streamlined struts Fastners, Hardware Yea, AN3-12A = - 22ca, AN4-154 64ea. AN4-17A ft fea. AN4-20A 24ea. AN4-22A 4ea. AN4-30A 150ea. AN365-428 nuts ~ ~ 16ea, AN365-1032 — 32ea AN960-10 washers - Fasteners, Hardware Cont, 28" 1/16" Cable 120' 3/32" Cable 42ea, 3/32" Coble Thimbles 42ea, 3/32" Cable Sleeves \2ea. Nylon Cable Fairleads & clips 10ca. 1” Pulleys, 3/32" cable 4ea. 2" pulleys,3/32" cable lea 24° pulley Sea. Turnbuckles, 24°x 3/4°x.065 SS (tail broce tabs) 4'x3/4" dia. Micarta red 18"x1"x1" 6061-T6 bar 18" x3/4"x3/4" 6061T6 bar V extruded alum. hinge elywond fea. 4x4" x.08mm . 4'x8'x1/4"Plywood (birch or Mahog.) 13 sheets 1/8" Plywood Spruce Cap Strips 2ea, 1 1/8"x7/8"x169" 2ea. 1°x7/B"x169" 2ea, 1°x3/4"x169" 2ea, 3/4°x3/4"x169" 2ea, 3/8'x7/8" x169" Zea, 3/8°x1"x169" AIL 169" pieces may be spliced to Reduce purchase price and shipping costs 14ea, 3/4°x3/4°x48" 4ea. 3/4"1/2"x60" 2ea 3/4°x5/16"x60" 100¢0. 1/4°x1/4"x60" 4ea. 1°x7/8"x48" fea. 3/4'x5/16"x36" 2ea. 2.3/4"x7/8"x40" 2ea, 3°x3/4"x30" lea, 43/4°X7/8"x24" lea. 4 1/8'x3/4"x24" o‘The Double Eagle 41 V-NDiagram - E ‘The V-N diagram describes the envelope of airspeeds and load factors (G-loading) to which the structure is designed. The airspeeds used in the analysis are as follows: a euver speed: Va =90 mph a 80 mph - a Vay = 102 mph Dive speed: Vp =112 mph ‘The load factors used are +4g and 2g, The corresponding V-N diagram is shown in Figure 4.1. Va = 22008 Nip =itseh L Load Factor fo) ] | 7 ir Velocity mph} Figure 4.1. V-N diagram for the Double EagleThe DOUBLE EAGLE is a two-place version ‘of the LEGAL EAGLE. Only a few parts are interchangeable such as seats and wing strut wheel firgs. It is powered by a four-cylinder 1835 VW engine. The power is approximately 60 horsepower. The wing area is 127 square feet and the wing spread is 28 feet 4 inches. Gross weight is set at 900 pounds and the wing is stressed for 4 G's. The tail surfaces are 10% larger than the LEGAL EAGLE. Construction is similar to the LEGAL EAGLE only a little more of it. The wing rigs are almost identical and wing construction is along the same lines. Wings are all wood with metal fittings. The fuselage, landing gear and tail, are all made with steel tubing that is welded. Covering is lightweight Dacron with a minimum paint job. The DOUBLE EAGLE will fill two places in light aircraft — an ultralite trainer or the new sportsman pilot rating. We in the United States are allowed to build our own custom-built airplanes because it is a learning process. Ifa plane calls for skills you now con't have, this is a chance for you to learn them. You will be glad you to..cihe time. Also itis a good excuse to THE DOUBLE EAGLE buy some of those tools you need for this job and have been desiring to purchase. To get started on construction, you will need a table to build on. | make mine freny 2 bv 4 with legs every four fect, two sheets of three-quarter inch plywood for the top, and two sheets of one- quatter ply for a shelf under for storage. On the legs | put a one-half inch hex head fag screw in the bottom of the lags fora leveling device. The weight of the table rests on these lag screws and the table is easily leveled with a good level and a crescent wrench. Level the table both across and lengthwise. (I buy cheap plywood and cover the lop wilh thin, smooth sheets of paneling, which is easily replaceable, when the tabletop gets unusable because of holes and ) This makes a teal nice work bench thal is four feet by sixteen feet. You can make a four-foot section that is removable if (em is limited. 1 only use the sixleen-loot lable when | am building wings, as they are fourteen feet long. One can remove this 4 x 4 section when not needed. This workbench also makes a very good table for hangar parties. We have used ‘ours many times for that purpose.‘The DOUBLE EAGLE can be built with regular shop tools, but the more tools you have, the more convenient the construction process will be, SUILDING A WING Be careful not to build two left wings, as it is easy to do. First | build all the ribs. The plans give full-size rib patterns and a rib jig board layout. Cul all the rib pieces befare you start to build ribs, Build one rib very carefully anid take it apart and use the pieces for patterns to make parts for the other ribs. Also make all the rib gussets al this time. This will seem like a fot of work, but it will be a timesaver when you do build the rest of the tibs. Number ail the pieces and put them in cans ot jars in back of the jig board and place them in order as you will use them while building the ribs. The gussets should be put in containers and placed by the part of the rib where they are to be used. Before gluing, be sure to make some glue samples from Scraps of wood. Pul glue on both pieces and clamp lightly. The next day, break the samples to be sure that the wood breaks and not the glue joints. It is a good idea to do this for every batch of glue “ou buy. There are a lot of good glues (hat will work very well. | recommend 188. Epoxy. | have also used Tight Bond II weatherproof glue with good resulls. When making rips, l'use a light duly hand stapler with one-quarler inch staples that | purchased at a Sears Hardware Store close by. Do no cut angle ends on the diagonal. This is not necessary, as the gussets will hold them. Just make the ends of the rib pieces a light push fit in the jig. After placing all the rib parts in the jig, slart gluing the gussets. Put glue on both pieces as this helps lo insure a well-welted joint. “If you use quick-grabbing glue, you can remove the rib in about 30 minutes to an hour and place the gussels on the other side. | always let my ribs dry overnight before | start cleaning them. Alter you have build several ribs, you can save lime by cleaning one rib while you are wailing for the one in the jig to tack up. 1 always sand the gussets and remove all the slaples and sand every Cap strip before using it for as a sanded piece of wood will take 70% less varnish over a non-sanded piece. Yes, | said 70%. You can make a sample test to prove this for yourself, just use Iwo same size pieces and varnish them both. You will find the unsanded piece will be much heavier. After all the ribs aio butt andsanded, you will have a pile of matching ribs that you will be proud of. Now you aro ready to stait on the spars. This is where you will need the long table. First screw a one by two along the worklable edge down the length of the table. This edge must be very straight and the edge of the table is a good guide for this. You canuse several short pieces but they must be aligned and straight. This board * used all throughout the wing building piucess as a guide, Cut and sand all the spar caps and rib station pieces. Make a block of wood about 2 inches by 3 inches and screw this on the lable about theee-quartors of an inch above the width of the spar. Make the front spars first, as it is the widest one. The extra space is for two wedges that pul pressure on the spar assembly whilo it is crying, After assembling all the spar pieces in this jig, you are ready to gue on the plywood web. The ends of these pieces are bul glued on a wide rib station. After glue is dry, one can remove the wedges sand remove the spar from the table jig. Now make the other front spar (CAUTION! This is where you can make two leit or right spars.) | use a method that works for me — | just put the ving to fuselage fittings on the other end of the table. This assures a pair of wing spars: The rear spars come nexl. Move the blocks down to about three-quarters inch of the width of the rear spars. Make the rear spars the same way as the front ones. Alter the spars are dry, one can move the blocks and wedges so they hold the spars in an upright position. You can plane an angle on this straight board along the bench edge. {lis uselul for one more time as an alignment for the front spar 2s the wing. is assembled and the spar is held with the wedges and blocks like they were while baing glued. WING SPAR SPLICES For better cost and shipping, the spar caps cen be spliced. The plans give the location of the splices. A twelve to one angle is recommended. A ten to one splice is the minimum. Carefully make the splices and glue them up at the time you are making the spars in the spar gluing jig. ASSEMBLY OF WING Having built all the ribs and spars, the spars need to have the fuselage and wing strut hardware located and trial bolted on. | make a wood jig to locate the outer allachment holes.This will assure a good alignment of the wings when they are bolted on the fuselage. The (hree-quarter inch holes can be drilled at this lime, Epoxy the Micarta spools in and sand or file the ends flush. Drill all the holes in the spars ona drill press, if possible. This will help assure tha! tke siraight hole you will make will be cyuate. Be sure to level your drill press both ways before drilling. After both spars are drilled, you are ready to assemble the wing. Start with marking the rib locations on the spars. Clamp. the front spar with the blocks and wedgas to hold it while assembling. Thread all the ribs on the roal spar and align thom squaro with the front spar. Now glue and nail the ribs on the spacers on the front spar at their marked locations. You can now install he compression struts. The location nearest the strut, altach points that have a strut on both sides of that rib. After all the compression struts are installed, you are ready for the diagonal braces. These have to be all filted and installed before you can glue them in because il will be necessary to move the wing to be able to install them. The diagonals are glued to the bottom spar cap wilh plywood gussets and wedge blocks. The trailing edge is next and the gussets to hold it against the rib ends. Put larger gussels where the corners of the aileron will be and nex! to the aileron cut out. The aileron spar can be installed at this point and the end fibs. Glue the aileron hinge blocks ‘on the ribs and diill them on a drill press for hole squareness. Also drill the wing blocks that will be supporting the aileron. Allow one-quarter inch space at each end of tne cioron for clearance. Drill and insert a piece of brass tubing in the aileron rib hinge bivci ivole. Take a one-quarter inch bolt to the hobby shop and select the brass tube that fits this bolt, On final assembly, the brass (ube will be filled with ‘wheel bearing grease. This will be a permanent lube job for the aileron hinge. Make and glue the aileron hinge blocks Before you cut the aileron out of the wing, drill through the aileron end ribs into the blocks to make an accurate hole for the bolts that are used for hinges. The heads of the pivot bolls are \o be drilled for safety wire. Also drill a hole in the wing blocks before the wing has been covered. A hole is cut for the inboard hinge pin in the bottom of the wing and patched. A doubler in the covering maxes a neater place to patch to. After the aileron has been cul oul of the wing, the front half round ribs can be glued on and the leading edge can be applied Remember to varnish the inside of the ply before.you glue it. After all this is dry, you are ready to apply plywood on the end lwo ribs. This makes a very good strong end of the wing. Sinall pieces of one-quarter plywood can be puton the insile to receive screws for the faring Strips or maybe a wing tip, The nose ribs are next: glue thoi on the fron! of the front spar. | stand tho wing on the trailing edge for this. “Gravity will help you with the nose ribs. Be sure to make the nose ribs fit the front edge of the spar. A nose rik goes at every rib location and one in the jiiddle ot the sibs to support the thin plywood wtigaround. There are two tibs al every place the plywood is bulled together. This gives a real good glue joint, Aiter the nose 1ib glue is dry, you are ready lo wrap the nose section with plywood. | sed four separate pieces. Ratcheting nylon straps are good for this. They are wrapped around the seal spar to get.a good wraparound pull on the resting edge. | use one ‘on every tib and staples. Then they can be used on another section of the wing. The leading edge ply should be vamished beiore gluing. Just put masking tape where the glue is to be and varnish. Also varnish the nose rios and front of the spar. Tape the ribs so as to prevent varnishing. a After the wing has dried, itis ready fora good clean up, sanding, and installing the metal fittings. On the end ribs you will have to cul away some vertical rib members to clear the wing to fusclage fillings. | add more quarter inch square pieces on top of these to {ill in boforo | cul oul, WOW! You gol a boautiful wing = one more to go. You are now ready for vamish. Two coats, first one thin and then a regular coat. | use Minwax Spar Varnish. After the varnish, the wing can be covered and painted te sult you. | recommend a lightweight covering and painting job. FUSELAGE Fuselage is welded 4130 Aircraft Tube. | use a torch as | believe this is the best meiiiod for aircralt steel. A straight line down the middle of your bench is where | start, Draw the bottom of the fuselage on this line and while itis flat, fill in up to number three station. Do not weld any joints on the fuselage until you have tacked up the whole fusolage. Use tacks only al first. Heal and bend the tubing at number three station, enough to be able to raise the tail up to the plans height. At this point, | mark longerthan necessary tubo for the tail post and secure it on the center line at the end of the table, This is to keep the correct height of the aft station and the alignment of the tail post. | jig the fuselage as | progress wilh two by fours, wire, nails, blocks, anything that | can make work. As I1do not like to spend a lol af ime making jigs, as they don't fly, | begrudge any time more than recessuiy building them. When installing tubes in ie Seal 2rea, make all the tubes thal are the same length at one lime and be sure they are the exact same length. This makes it easy to keep thal section square. Add the other tube as per the plans, the eight wing landing gear fittings, all ihe various tabs and control fittings that are required to finish the fuselage. If you use go cart brakes, you can follow the plans. Other types and you are on your own. 1 used the go cart brakes because | Had them. Many others will’also work. The ear wing strut filing can be held in alignment with threaded rod and many nuts to hold the correct distances called for in the plans. It will be required to enlarge the fittings for proper fit on the fuselage- longerons. While welding the fuselage clusters you will find that those clusters will be difficull to get proper heat to make acceptable welds. | use a propane torch sel to play its flame on the other side thal | am welding. With this extra heat on {he joint, you will be able to make good welds After the fuselage is completely welded, you may notice thal some of the tubing is bowed out or in. This is corrected by heat, or just by tapping it with a two by four and a soft hammer. 4130 tube is casy to work with and can be put back in the proper place with a litt: persuasion — heat and force applied with care, Don't panic if yours doesn't look straight. Just try working the kinks out. The fuselage should be blasted and primed with 2 paint that will not be affected by the glue and paint used in the covering process. LANDING GEAR Landing gear tubing is of a heavier wall thickness o be able to take the loads that are put on it during not-so-good landings. The wheels are Schwinn Workman heavy-duty bicycle wheels used in many industries. The bike usually had a big tool bo» in front with the wheels on each side of the toc box. They have ball beatings and require revular adjustments and Grease. The landing gea: lube on the front should be made in pairs and sel at the sameangle whilo welding. The shock strut is sinple once it is studied. The die spring number is given in the plans. The spring should be pre- loaded about three- quarters inch to start. Later it can be adjusted if it is deflected the empty weight of the completed aircralt. The spring should hold the plane without being deflected at its empty weight. Also, it should not hit bottom when loaded. Be sure to align the wheels straight ahead. Toe in is bad but a little toe out is okay, but not too much. TAIL FEATHERS The fin has 5/8ths leading edge and % rear spar. The ribs are bent up sheet steel. A mild steclis okay. They are tapered when bont [Link] to fit the spars. Make these from eighteen thousands to twenty-four thousands — whatever you can locate. I got mine from a scrap pile at a local lin shop. Welding the thin ribs to the much heavier spars can be tricky, but with a. little practice you won't have much trouble making good welds. The ribs in the fin all have the edge downward except the boltom one. Itfaces [Link] allow the covering a better place to be atlached There are two pieces of tubing welded at the top of the upper ribs next to the spars. These hold (he bolls for the tail brace wires. Leave these wider than the spars so they stick through the covering about one-eighth inch. Also tho hinge half's must be slipped on and the placed where they belong. | use a piece of masking tape to hold them in place. The rudder hinges are aligned on the fuselage. Match the leading edge of the fin to the front mount on the fuselage. THE RUDDER The rudder is built similar to the Fin. It has three quarters front spar and a three-sighths trailing edge. The control horn 1s one-e¥jhth steel welded to the spar on both sides. STABILIZER ‘The stabilizer also has a three-quarters rear Spar and a five eighth front spar and tubes for the brace wires. ELEVATOR The elevator will be the most difficult to construct as it has a lot of welding and tends to distor! from all the heat. | was able to straighten mine wilh applying heat to the outside of the bends and helping it with gentle pulling andpushing. Don't forget to slip the hinges on before tlattening the ends. HINGES The hinges are made by welding two picces of tubing lengthwise on both sides, then sawing them into %* pieces. Place lwo pieces on one, spar and one on the other matching spar. This makes a very sturdy hinge and the best part is you make it yoursell. Eye bolts and other type Hinges are expensive and are not better. COVERING iter every part is painted or varnished, you can cover it. | use the Poly Fiber method but you may choose lo go with another method. Be sure to follow their directions. With the Poly Fiber method, | use Poly Tac to glue the cloih to the structure. | only glue on the outside edges. | have a video that shows this. Poly Brush is next. Be sure to brush the first coat on after the fiber has been shrunk. Brushing helps remove any mil oils. The first coat holds all the remaining coats, so it needs to be brushed down through the weave, Always keep a wet brush with Poly Brush as it dries quickly and will rope badly if he brush is semidty. The second coat of Poly Brush comes after the tapes and patches are on. They are glued with Poly Brush, Somewhere in the Poly Brush stage one must glue the drain grommets on. They are made of acetate and can be glued lo the fabric with Poly Tac or Poly Brush. Some drain grommets are flal like a washer. | use the “seaplane type" that have a cup on them (o help remove any inoisture that may build in the wing while you fly. One can lightly sand any ime with a very fine grit paper. After the Polly Brush comes Poly Spray which is a Silver Color. The ironing is over al (his slage as the silver wil It if touched with an iron. But one can do much sanding on the silver coals. | slop at the silver usually afler (wo cross coats. INSTRUMENTS. | recommend a minimum amount of instruments. | use an altimeter gauge, air speed indicator, compass, and for the engine, oil lemperature gauge, oil pressure gaugo, tachometer, and at first maybe a cylinder head temperature gauge and an exhaust gas temperature gauge. Olher inslruments are really not necessary.STRUTS ‘The struts are fiom Mrs. Carlson of Cailson Aircraft in Ohio - a three-inch for the front and a two-inch for the rear. They have aluminum blocks in each end for altaching. Be sure to check for straightness as some twist as they are being extruded. ENGINE The engine | use is the old reliable Volkswagen Beelle engine. | use new cylinders and heads. The bottom end can be made up out cf soiviccable parts, as they are very reiiabie. Cire can always buy new parts to build your engine, Or there are pre-built engines to be bough!. | build the intake manifold with a kit from the Great Plains V.V/. The exhaust system is also trom Great Plains. | fabicata the altemator and carburetor heat brackets. A Kubota tractor alternator furnishes plenty of amps. For the ignition and radio if installed, ‘There is no starter. | always stand behind the Propeller and start the engine with my leit hand while the right hand is free to operate the throttle and or switches. An engine that is in good order vail nol be hard to start and there is no need for a starter. The intake castings and carburetor are also from the Great Plains Aireralt. The generator pulley on the rear of the engine is a hardware store item. The distributor coil and plug wires are a very reasonable purchase. Check them in Hot _V.W.'s Magazine. With batlery ignition, you set the spark plug gap at -035. With a magneto, they are sel al 018. The battery ignition is twice as strong as a magneto, ‘A weak spark has been blamed for valve problems in V.W.’s. I don't recommend oil liters or bigger than stock oil pumps. High oil pressure takes power from the engine. | change oil every twenty-five hours. Also check the points and valve tappet clearance at this ine. ‘This is a very simple and reliable system. There is No need for exotic parts or systems as thoy are cosily and replacement paris are difficult ta find. FIREWALL The firewall is made trom .025 galvanized Steel (016 stainless steel also works). The measurements are in the plans. Be sure to check your No. 1 station for an exact fit, The top flange is bent to the windshield angle and thewindshield is tucked under it and bolted. The olher flanges are bent to the fuselage angles. They protect the covering at the front of the fuselage. WINDSHIELD | used 1/16" Lexan and bent il in a sheet- metal brake. Buy one sheet and use the scraps for the wing joint cover top and bottom to allow a view ol lhe fuel gauges in the space between the wings. Use a plastic drill or a bradpoint one to koap the holes clean and no cracks in the Plastic, Use a bandsaw with fine tooth blade or ‘an abrasive cut-ofl tool to cut Lexan. Do not use a teciprocating saw — you wont like i. Always check the scrap pile al the plastics place. They might have a partial sheet you can buy al a good price, WIRING Plan sheet No, 45 shows the wiring plan | used. WEIGHT AND BALANCE The center of gravity (CG) ol an airplane is very critical to its ability to be controlled, To find the empty weight center of gravity of an airplane, first level the plane in both directions (forward and sideways). The Double Eagle's leveling spots are on the backbone of the fuselage and across the seats. Ina level position, drop.a plumb bob from the {ront of the prop to the floor. Mark the spot wilh. chalk, then drop the bob at the wheel axles. Mark that spot on the floor Also, mark the floor at the axle of the tailwheel. The front of the prop is the datum line; all distances are measured from that mark. Measure the distance to the frant whee's axle and record it. Measure to the taiiwheel mark and record it. One scale can be used to take the weights at the three wheels. Being careful to keep the plane level, record the weight of the plane al each of the wheels (ane at a irre using one scale). Having recorded the three weights {in pounds) and their respective distan:es from tho datum fie (i inchos), multiply oaca woight by its distance to give you its moment aim. Total the three weights and the three moment arms, Divide’ the total moment arms by the total weights; this yields the location of the venter of Gravily as measured from the datum line (lront of propeller). Measure that distance fom theih wali Bom Wher Ow ENLiNet Gavty tals on the wing My tron wheel Weights totaled 975 pounds: tho taboo! weighed 14 pounds. Front wheal Imetnent arms equaled 1980.8 inches. anc laiwheel moment arm was 2849 inches: ‘ion a total moment’ arm of 887048 inches. ‘Toa empty weight was 009.2 pounds. otal moment aim (22794.8) divided by total emmy weiaht (990.2) equate 684 Inchon, which is vory close to the front wing moun. With the adciton of two 200 pound pilots and 19 gallons of fuel, the CG mcatery dcceranicn) or ivconyried 199k ec or x ‘Beto dene a the work ou ulti hdl chedl se to Louris, Thue dcrnertaton ie an-enamie a insert eI oat iny Orbe {Emnte Uivaight i daes natimply hat he bir at nn UNFaant of page have ne erosion wl voy tn sary "he oan tse toe lomo nit oen movtnoatesy si atslyHentmay result Species, my 10 suger tpt tha thay Bocce ata fe ni i hin i Wie deo de st rect dua tote sinpcty. Wey hor an aie ‘nda la tye manstaetine a rocerd ana nse al sence nil gna aac tabytnarotom. My ee Sie ere epoesite is sul ina ale range 1ov doc control response. it you deshe to cary a litle baggage. » small box ean be Installed in [ront of the seats. At no lime add any weight Behind the seats as thi may lend to make the plane have an aft center of gravity, Acrobatics are not recommenced. Hemember: get the distance, got the vcights, get the moments, Divide the moments (in inches) by he weight (in pounds) and you have the center of urawity, Good Luck, LIE. Milhottand TE tihtinalcthioy Shona vel bo feynotosed whale “eer hat ‘Scupo te ert fo thw folund ot purchase pica ! urs pans, es bur cosl ck spn ar neo. Hoa! ‘ret an re ina ree on refersectin fined cension inn ly ate tr ues een to 99 praenseat No reqosts yes Procosagu Hts pian are muon mags, natay, go, glover Monin! or oer 30 ety oa a,c ey mln tasty Avery OF Shipment oth fociALL MEASUAEMENT’S CENTER TO CENALL MEASLFEMENT’S CEN TO CENTER CORRECTS —B-OF Lem FUSELAGE£2 Ve VA Te VEEN OF STN PLAT FRAME BEFORE BENDING) CORRECTED — P-OF mpamnpuneetnegutinececmmetiie i as nnn =o L an = OuNT, rile FIT REAR pas Ta ated fio TOWING STF aera ; . Uy 1 -STAB. MOUNTS — L OUSHINGS wir H } X HOLES WELD &) @) IW KONGREN. STAB FUSELAGE STATIONS BOLTS ON ADJUST WITH WASHERS DOUBLE E. E AGI ANGLE VIEW|, —_____. 2179 4pPeox._______________} Qo | FIT TO YOUR WiNS. hiv Le ~\_ BusHiNiss ARE $ ae WITH 33" HOLE ay a WELD ALL AROUND STATION 3 STATION 2 Lf & EAGh WING MOUNT- mS f AS WELD STRAPS .035- xE Ts / ff MOTOR MOUNTS WELD IN 2 oRNERS [ ye | 14 Is es L T 3 he ; —S as ee L ae | 40" 4o We 4 STATION NO. STATION NOC SHDPY | | | ¢ | % No & STATION 07 STATION DOUBLE EAGLE No A STATION No. § STATION NO -6 STATICK FUSELAGE STATIONSWELD GE qe KD IE ANOLE Z THICIS Le La Ex SLs = a Hs TAIL WHEEL SPRING ERACKET - BOTTOM FUSELACE DIAGIONALS ARE % EXCEPT SEAT AREA IS 3 —————— DOUBLE EAGLE FUSELAGE TUBEING TsVUIRESHELD. & i] des 23" BEND 7 O6 SANLESS OR GALVAZE STEEL.O2S oe ° NATCH TONOE 7 STATION co REG MOUNT nese] AE cecn your NOI SATION FOR DIMENTIONS.STATION s > = CUB TYPE CABLE CHIE. WC “= SNAP _ RING SECURES GUIDES ELEVATOR CABLE GUIDES CO” ON MAKE S ynete “ae MAKE 2 Fo, i STATION & x oe corre 09 EBs SEAT AREA O55 STEEL E EAGLE CABLE GUIDESSMALL TOOL BOK HERE OK I FRONT OF SEAT 80TH SIDESPosse yt (AJREAR Sick star TAXESNYLON CUG TYPE CABLE SUIDES SECURE WITH COTTER Piit AND SIP. RING T" STICK FROM -O35 STEEL NOTCH TUBE Pe FOR PULLEY) HRA rr Ne PRO AILERON HORN CUT FRON: iN SRURRE TUBE 222 \ A! D2 euSHN € HOLE SLOVS |ad! / af om DRILL Hetil SA oss Fos ER CY, woz vamamee tell Gee here a Eo - : STICK BRACKET SERED CRE MAKE 4 062 ST DOUBLE FAG = STICK DETALSaad | Ce eo Syl Gans HOLE, | 8% FO % | te O35 seas » an MAKE 2 FOR SIAL 5 al | (OEE QUBLE EAGLE | BRACKETS ee FOR 2 PULLEYS [RODDER_CABLE085 WALL | at ARMs eRon #'TUBE 2 oY » sco Na) BLE T1B8 FOR BRAKE CABLE HOUSING [BRAKE HANDLES |SEATS FROM .O16 ALUM. |"STRIPS BASKET WEAVE ET WITH FOP OR SOLID RMETS MAKE TWO 18 PUCES 40°46 18" THS MAKES AVERY GOOD = SEAT ABOUT ONE POUND ~~” DRAPE OVER SEAT RAILS " RIVET OR BOLT ENDS ADIWST jo YOUR HEIGHT AND HEIST 7 a a ‘ /* ote aun. sreies_)aa MAKE It TASS ~"2 OR INSTRUNENT PANEL " ae xe a MaKe 3 Tas FOR pases BoAROS USE FADS BETWWEENTABS AND WINDSHIELD FAD FRONT CORNERS WITH FELT [DOUBLE EAGLE | WINDSHIELD “TABS» ry FULL SCALE “erictr? “By cere @ REQUIRED STACK DAILL IN PAIRS | XI | : a ; s>thaes AT NO.2 STATION at : =e 37s, 2E 48 | A WNSAND SERA —3+0 ) TTS MES : 7) 8-F STEEL AION | Entel PNSTRUT J sal FRONT FI TINGS HOLD WING STRUS, _ AARGEAR: REAR ONES HOLD AING “ier STRUT GEAR LEG AND All. elt suers ATS Wo, BSTATIONCONT, eee MOUNT. - . MOUNT TUBES #047 MAKE4 STEEL IS ip = fee, MAKE ae HOLE cA WELD TC TUGING “1 “DOUETE EAGLE | TENGNE MOUNT' va G@) PULLEY GRACKET i o/ | cup type FAimiesos Lo | (oe | 7 see PAGE 6 g ¥ { © ores TH OKO) eau | “— BEARING PULE' Sy) COTTERPIN SECURES, CME 7 To Pay aRove —— j ——— f [DOUBLE EAGIE RUDDER CABLEies i AinATOR STATIN 8 SS CABLE END Tye Or1—STICH AP Bur N i | ee eS SS TYPE BUSHINGS Seay SP marten HO" 4 _AICUPRESS OVAL SLEEVE Xp BUSHINS HERE fe | FORSTICK STOP | i ADJUST Vi O CONTROL CABLES ATTACH HERE. DIFFERENT SIZES =i ae a cK ASSEMBLY Sines [ELEVATOR CABLES |oss 34 TUE A Sree RUDDER, CAGLE O35 STEEL TAS DOUBLE EAGLE {RUDDER PEDALSre a AitiatoR DOU STOP 4/30% 5 A aye wine Oy / xy uppeg “ ‘ cos 3 STATION 3 wergr 4 GOL AOJUSTABLE # BUSHINGS ARE i UeTH eee j SN ange aoshins 50 GOL HAD HITS. oth ALERON HORN SQUARE is ak BEND AND WED . \Kezes RuoceR| rs Pas FROM. HTS WG ELEVATOR ne 40 TRAVEL = 30° gl eh 207s WAYS sal of USE 4° GOLTS. FOR AILERON STO? ADJUST TO 30° OF POR LEG CLEARNCE WE AN/BOLTS: THREADS EXTENED Tass # steee 4174 / LOTS LEG (tenes) DOUBLE EAGIE | (DeONTROESTOPS |SRAKE BAND RE GEAR LEG MAKE 2 WING STRUT-CR 2 _fisoungs 9p. 079 420 5 \ FIT AGAINST GEAR BRACE 10h SHOLE FOR i BRAKE ABLE Xf Row ne “ADJUST CAMBER ae FLATTEN ENDS ~~ WITH THIS TUBE AS NEEDEDWORKMAN 20°SCHW) aie ORES io 1 al mie ZEA. YOURE moa = ia CO CART BRAKE 1 | peat 7g 6OV CUT _ToP OF STRUT. Td Fit 2.0) BEND ENDS OVER (HELD a5 = MAKE COVER ez: iy HOLE #130 STEEL 079 WALL We <- ‘STEEL PLATE eS STRUT Za\| what NE THREADS mie — IO | ale hy i COVER Fan LU i pF | eS oi eer oe 2S ee a_i RONT VIEW OR FIT TO YOUR WHEEL(2. “MANUAL, BRAKES HYDRAULIC BRAKES: ta ARE OPTIONAL ~ DRUM CLAMPS GO ON eAAKE, HANDLE oe “hi eee et al IDF OF = 2 70 GEAR i INSIDE OF SPOKES TO CLANIP + Ey "ADEL CLAMPS DRUM. CENTER DRUM : HEAVY DUTY CHOKE Sy CABLE | WITH SPACER Sioes \ Sie CABLE BUSHING PMICOPRESS SLEVE FA cary BRAKE BAND | il es ~~ | a Axe Bots i CaS A | 1S HEAVY DUTY, Se KY ge a ss Seawe Colles hee © A STEEL. CLAM . KAS Met DRULLTAP £28 4°30 CART cD & ey : FROM BOUING BICYCLE (Me, DOUBLE EASE | PASALEWETYCI 4 SOUT HOUSTEN OAD T2502 SEMEL eS |PLACE INSTRUMENTS TO SUITE YOU (MAIUM INSTURMENTS: ARE™ OIL PRESSURE OILTEMP~ AIRSPEED ALTIMETER. TACH. ~Ie SS munya SS LN Eg —"WELD TASS ON St CROSS MEMBER ae ooo FOR MAUNTING Sp > OS, 7 L FROM $ MARINE PLYWOOD-PAINT OPTIONAL_______| PANEL FROM $ MARINE PLYWNoO0D-AI SE ESE INSTRUMENT PANEL |Bee “Welel od 1 “este rere forme a eur OUT git “Oc. aE Ce TYR HINGE MAKE PSETS 21 REE: 3 Naot ER FUSELAGE | i “Wgotrom TOseNTER | © ion HINGES TO FIN AND FUSELAS TAIL Po. 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HOLE J" pucus ses HHT g meu Neigg unter ST wel rae, a weldTo Rem weleTo a RiM TAG ICES TRE ARM, YaaTO AVOID SHIMMY TAILWHEEL SHOULD HAVE 2° CASTER [erosive USE STEARING SPRINGS OF DIFFERENT SIZE FOR SHIMMIY DAMPING Lf i Cn ; ™ = 4,8 well bk x 7 “= \ FROM £ CONDUIT ~ SLIPS IN ("STICK— COMPLETE ONE END ATTACH OTHER EN ALIGN. Talk THEN CRIMP SLEVE FOR A NO TURNBUCKLE TAIL kh sae STEEL coRRReT ANSLE +) Sono ee oS Saou 2 BEND To AND CLAMP ae See WIR“al [ Le — Ag Lo IRE I EP fA I s8MM Perv wood LEADING eee | 2] ae —+ MAKE 28RIBS — MANE S2 NOSE Rigs — DOUBLE NOSE RIBS | AT PLYWOOD JOINTS — GLUE A NOSE RIB BETWEEN RIBS TO SUSPPCRTLEADING EDGE WINGS ARE LEVEL AT TIPS WINGS HAVE HEDRAL [Boere ee SET WING WASHCUT WITH-REARSTAa; EAS WO WB HERE afSPRUCE ERE mer Scunse COMPRESSION oe NOS RIB eethy EONS z PxZ-COMPRESSION AND DIAGONAL GLUEWVGE<2F SQUARE PLYWOOD TOP ON FRONT SHIR — BOTTOM ON REAR SPAR COMPRESSION RIBS ARE GLUED TRWING RIBS EVER WHERE THEY TOUCH USE SPADERS IF NEEDED DOUBLE EAGLE BEGONAL DETAILS> BLUE TWO RIBS TOGETHER AT EACH . LEADING EDGE. JOINT FOR BETTER GLUEING INSTAL NOSE RIB BETWEEN WING BIBS IN LEADING EDGE FOR STRONS ~D-SECTION DRILL £ HOLES — USE FORSNER et 1G) | oh se Fe on PATTERN FROM # — ROUGH CUT RIBS TRIM WITH ROUTER USE A BALL BEARING CUTTER NOSE RB, a MAKE 52—FROM 2-PLY, DRAINAGE HOLCHUSE SCRIP WOOD BLOCKS ALLOW ROOM FOR JA CAPSTRIPS SS Exe pe, capsTnes——_ A ow F © SLUE on THIS STAPLE ONLY I aXOW ROOM FOR SPA? TO SLIDERIB JIG PATTERN ALINE BOTTOM USE M FOR ACCURATE RB RIBS MADE FROM ¥, SQUARE WOOD CUSSETS ARE .6MM EASUREMENTS = Km =. PLYWOOD SPAR WEBEL. > PLY WOOD SPAR CAPS SEE SPAR PAGE \~ we 5 SS Wy" eymeer BLOCK FoR EACH RIS La Naie ro SPAR peGUSSETS ARE GLUED AND STAPLED. SEARS LIGHT DUTY STAPLER NO. 68428 STAPLES NO.74424MAKE COPIES USE TO BYLD RIBS ON. ALIGN DRAWING USE BOTTOM MEASUREMENT “AND MAKE SPARS SQUARE _VATH BOTTOM 7 .AILERON NOSE RIB . O MAKE 8 As HOLE SAW C) WORKS WELL CUT WITH & BLADE ADJUST HEIGHT SO O Ply COVER FITS AILERON NOSE RIB HOLES OPTIONALBUTT SHEETS END TO END FILL IN GAPS ' FOR ACCURATE RIB PATTERN | ~ = RIB END AILERON HINGE — SOIT : _ 3x SPARC SEDC @ all == ES It Ke of ! FRONT TOP FRONT BOTTOM REAR TOP REAR BOTTOM ~% CL REAR Tor. i SPAR CARS CAN GE SUED TLS (st REAR GOTTCh 1 7210 5 Of esofef z REAR SPAR 2" THOLES qeZiecd O00 of gl. — FRONT SPAR ,. 3° HOLES T_DOUBLE_E Se SPARS AN,= : FI , “CRONT SPAR AT STRUT ATTACH LOCATION” 3 BRON PLYWOOD - GLUE CVER FILLER Block GRAIN PARALLEL 70 SPAR CARS \ z S 4 | FULLER BLOCK SPRUCE OR FIZ VS GRAIN PARALLEL TOSPAR CAPS le 7% FROM BUT RIB MAKE TWO ‘i & q re | 1o-——$—+ 20" f to! | MAKE 4 fe? FRONT SPAR CAPS SPRUCE DOUBLE EAGLE (SPAR DOUBLERSREAR SPAR AT STRUT AT TACHVENT f PLYWOOD OVER FILLER —AS FRONT SPAR i re atic |_| atl " t » SP SPRUCE 4 x 3 y DOUBLE EAGLF | SEAR DOUBLERSTRUT MOUNT - FRONT SPAR - MAKE @ STRAPS AND 4 PLATES & STEEL es <= REINFORCEMENT PLATE MAKE 4 & 4190 STEELoS Gra) FULL SCALE” a FRONT SPAR PLATE MAKE 4 ¢ STEEL (430) STACK DRILL IN PRS FOR ACCURATE FIT || SPAR FITTING 70 FUSELAGE Leigh MAKE 8® ao SPAR WING /FUSELAGE-ATTACHMENT 8 STEEL 4130 WELD TO STRAP. \ ONE PIECE OPTIONAL i | | | | ee FULL SCALE MAKE 8 STACK DALL > IN FAIRS LIGHTING HOLES OPTIONAL . |REAR SPAR STRUT _ FITTING FULL SCALE £4 $STEEL -4130-— ©) ; Y fe = STACK DRILL FOR ACCURACY DOUBLE EAGLEPHENOLIC INSERTS MAKE ZO SEE TECH FOR BY yo LOCATION AND SPAR DRILLING INFO ~4 HOLE BUY 48! HEAIY CANVAS ARENOLIO. ROD MAKE A TEST HOLE INSC@AP WOOD [DOUBLE EAGLE | FORA LUSH FIT - EPOXY (= \PHENOLIC INSERTS’ |RIGHT SPAR % _FUSELASE END er oy) PY Sphices a) ¢ RIGHT We S L : = Ee ° f : ee L §, oN BOLT ONE BOLT HOLDS BOTH SPARS To FUSELAGE REAR SPARS ARE SAMEUSE AS A PATTERN MAKE SAME AS RIBS AILERON HOM ARSON ENG RIBS FULL SIZE| KibOTA ALT “SHALL TRACTOR €G1800) aT NO. IS531-6 4015 a= PART NO= SSS -EFEOO INSTTON: _AStESSORY ps Suntec K ee 2 us € 7 Lane a f 2 * a Atle (Bea - yy Owe (veer METER ae ae £ f + Fa ¢ iid ACCESSORES HAVE OVI! SWATCHES foes 19) comes BY nate? @FOR AILERON HINGE PROCEQURE OS ® CHECK THE TEXT o GLUE IN & PLYWOOD REIWORCEMENT = oS CUT BOARD HINGE BLOCK ee 3°X4 BOLT FOR HINGE PIN < fs CUTOFF THREADS ORILLHEAD FOR SAFETY WIRE C| f BIE FE 1 | ws kl! [OUT BOARD ALERON | fiom TREKS OW ASSEMBLY] 4 I “HINGE BLOCK@ eee a (ALIN THIS eee LIN wip \ WITH ERE a AILERON HINGE B4 Wey Celaya a yT_OUT FOR ake cur 10 FIT EEE | BETWEEN. PISS CB XL, Z 7 v vo Sule TO Hereyshee RIB AILERON (END RB | —— [DOUBLE EAGE AILERON = SPAR i =I& @) y JURY STRUT WING_FITTING }6 ALUM. ANGLE MAKE ¢ WHEN. MOUNTING Holes DRILL THROUSE SPAR WEB USE WOOD WASHERS ON BACK. 4 | Hy Holes 1 } “ . a Ny ie oo z = BELOW f io he, hippy aad aa i Sfetole JURY STRUT WING SPAR BLOCK ye EPOXY IN 54"FROM NOIR eee EA FRONT AND REAR SPAR* hes URY STRUT Ef| MADE MY. FUE|. TANK FROM KLEGA’ A HIGH DENSITY FOAM SEE & FIBER GLASS TANK WOULD DO MAKE CARDBOARD TAMK CO WITH FIBER GLASS. FILL WITH WATER TO DISOLVE CARDBOARD, TANK FITS BETWEEN | AND2 RIBS IN BOTH WINGS: SCREW TO. PLASTIC FRONT SPAR AND DIAGIONAL ip a | FIT TANK Tt YOUR WING 6" PPR tee ee ov ne EASE LEIKE ibe aS aeCOVER GAP “WITH . O16 AL UM TOP AND BOTTOM LEAVE SPACE ON BOTTOM TO VIEW FUEL GAGE-COVER WITH LEXAN MAKE WING END PLA BIGGER THAN WINS TIP aie BOTH TIPS & CUT LIGHTENNGHOLES z WING GAP COVER NeS ste Gea FOR STREAMLINED STRUTS CALL MRS CARLSON POBOX #8 FAST PALESTINE O# 4817 530263994 |GeaekeTs ~_\ BEAR SPARATTUGS SM \_, HIVE I ANbLE 28 et i ALERON ‘ BELL CRANK \ ik \ \ by MS \ \ AN M LOL ES FoR \ ae _ \ AUERON cABLE SR \ \woe\\ aa \ EXTRUDED ALUM. STRUTS 6061 T6 - ALUM. Buy 24" oi up HOE, Alum. BILLET | ALUMABLOGK “FRONT ONE HOLE AUGN STRUT DRILL SECOND HOLE LBOURLE FAG {| STRUTS524 + AILERON CABLE GUIDES USE CUB TYPE NYLON INSERTS SEE PAGE © MAKE 4 BOLT UNDER REAR STRUT £ 5p re JS Yu thiee Z } al rari ae SEE PAGE 6 [NouarE FAG —| 1) i Ff GUDES)) - 63) wis ae —— : FoR STREAMLINED STRUTS CALL MES CARLSON BOX 88 oats 04263836 BUY 4/ECES 86" TRIM Be Wes YOURE PLANE WRAP A SQUEZE iN. ee —. [% / / oy 4 ReCES xN 495, Bans zie eer (—S Se “ONS 3" FOR FRONT TRIM FROM 025 Bunnie ! ALUM. JURY STRUT SLIPS ~ OVER SS TABS MAKE BAND FIT SHUG PLASTIC TAPE UNDER [BSLECE acs | RY STRUTS |“BELL (CRANK Ft ALUM. BELL CRANK BEARING RIVET = PLACES / AN2IBP4 ff! HOLE, y Oy e JEND DOWN /"TOCLEAR STRUTa ph he PURLEY EXTENDER MAKE 2 A130 STEEL 65) y A) masts Cae, ce wee cae t | |e | | | key te ® ee wine) he es Flos Fyroues We aw fa 7 CR, AUTO PARTS: 4150 STEELZ | 4S ALUN. MAES xs SS THIS PULLEY LOWER if m Avs a ei Das i a & “ a 2 LIES WITHCABLE GuaRDS THREE TURNSUCKLES MOUNZON REFER GEAR FITTINGSDEFECTOR WINGS L oe BOTH SES [ Sa oe — 4s° 4 Se MEASURMENTS ARE APPROXIMATE & LEYAN~DRILL LARGE HOLES-USE RUBBER GROMMETS BEND IN SHEETMETAL BREAK BEFORE REMOVING PAPER Faounr Tale [WINDSHIFED: “ee 7 an —+| DATUM IS FRONT QF PROP. | ‘TeRxoss | ene went | boas C ) Md 6 | Fee] [havens [7 TAIL (ie ees Th Ween! rene” liand| w= lass. eidee 2 |. goo |sros lis Tz sles? ES ee —} ato’ Sag | 9942.8 lager | | GROSS WT SHOULD FALL IN FIRST 14 INCHES NO WEIGHT REAR OF SEATSSHRINK fT PROP. HUBS NO MACHINING NEEDED HUB, F RONT PL. AND INSTRUCTIONS $165.00 COMPLE” E P.P.