Xpress builds a 115 AJ Laser - PICTURE HEAVY!

[Xpress]

More work last night. I'm almost to a standstill, aside from the throttle/choke servos. Waiting on the servos to arrive still....

First up, installing the 2 HSB-9381TH servos I had. These went right to the rudder slot to get fuselage setup out of the way as quickly as possible. I used black socket head servo screws from TDRC.

Fuel tank was next. It's a TDRC 50oz, plenty for the 180. It's been sitting for a SoCal Minute so rebuilding it was necessary. New internals and a good cleaning with some fuel and it's ready to go.

Before (you can see some of the old fuel in the bottom left corner of the tank):

After (all clean, but the moisture in the air made the tank fog up inside):

Tank is secured using blue velcro tape from, you guessed it, TDRC. Below the tank sits a strip of creative foam that I normally use for engine baffles. Just cut to shape and it's secured with a small dab of foam-tac.

Lastly I fashioned a plywood plate to screw in place over the rudder servo tray to hide the wires.

Hopefully I'll find a minute to work on installing engine servos over the weekend, still to do:

-Plumb fuel tank (will happen after setting up carb servos)
-Install fuel dot (will probably use McFueler again)
-Install rx and batteries
-Setup wings
-Setup stabs
-Setup rudder
-Install exhaust (I will probably go canisters since compact mufflers are no longer available)
-Cut cowl and install low pressure lip
-Baffle engine
-Bolt prop on, test/tune engine
-Go fly

 

[Xpress]

Essential supplies for this building operation

 

[Xpress]

Glued the control horns into the right wing panel last night. My process is pretty straightforward- slice the slots open for the control horns in the surface, test fit the horns and make any adjustments necessary, then put the horns and the square horn base (for lack of a better term) into the slot again. Trace around the square horn base with a sharp hobby knife, then pull the horns out and lift the freshly cut square of covering away from the surface.

Next up, slap some blue masking tape down around the square cutout, then sand the gluing surfaces of the control horns and square with 150 grit sandpaper. Scuff until they're not shiny anymore. Mix up some 30 minute epoxy inside of a sandwich bag, then squirt it into your dental syringe- nip the tip of the syringe off to open it up, then use the syringe to liberally apply epoxy to all gluing surfaces on the control surface and the control horn. Set the horns in place, using a ball link to keep them aligned.

After about 30 minutes the epoxy will thicken up enough to let you peel the tape away, which will peel the excess epoxy right up with it. Some rubbing alcohol on a paper towel will wipe away any little bits of excess epoxy here and there.

Just one more surface to glue horns into before it's ready for servos

 

[stangflyer]

What you need for the Dremel when cutting big lumber in that manner is one of these, https://www.dremel.com/en_US/products/-/show-product/accessories/ms400-multisaw-attachment . It is basically a miniature reciprocating saw, and works great.

Nice... I could use one of those for sure.

 

[stangflyer]

Nice plane. But then I would not have expected less. Actually been looking at that plane for a while. But heck...too many now. I really have not time for a new build. LOL. Looks nice Tanner. Keep up the good work.

 

[dhal22]

Nice plane. But then I would not have expected less. Actually been looking at that plane for a while. But heck...too many now. I really have not time for a new build. LOL. Looks nice Tanner. Keep up the good work.

Too many? What language is that please? I see English letters but can't find an explanation of them assembled like that anywhere.

 

[Bartman]

Looking good Tanner! A buddy of mine just got the AJ 86" ARS and he's been telling me what a high quality product it is.

 

[Xpress]

Looking good Tanner! A buddy of mine just got the AJ 86" ARS and he's been telling me what a high quality product it is.

The quality on these airplanes is definitely top tier, it's why I've chosen to fly AJ Aircraft exclusively. The guys are extremely friendly and very helpful as well- I was missing a parts bag out of this kit and they rushed one to me to keep me from being held up. Funny enough, it's on my end of things that is keeping me from progressing forward!! Thankfully, it's looking like more servos are set to arrive next week

I'm pretty much at a standstill until more HSB-9381TH's show up, other than those I really only have a few more things that need to be procured before the airplane will be flight worthy:

1. Servo arms
2. Exhaust system
3. Channel expander

It's a good thing the CA DMV has had registration tax increases this year, otherwise I'd have more 115 Laser parts to sit on in the meantime!!!

 

[Xpress]

Did a little time lapse on how I glue control horns into the surfaces.

 

[karolh]

A very nice and detailed build thread and looking forward to seeing this bird in the air.