OSMW SpadPort Build

[msatin]

This is another Old School Model Works project.
https://www.oldschoolmodels.com/sfb.htm
As I've pointed out in other OSMW builds, the reasons I like these kits are, the laser cutting is excellent, the manual is detailed, and there are hi-res pics of many of the steps posted on-line
https://www.oldschoolmodels.com/mpics/sfb/
Overall this was a relatively straightforward build, but there were some challenges that I will point out.
1 - It's enjoyable to see a stack of balsa and ply get smaller as the project progresses.
2&3 - The wings have metal straps that the wing struts will attach to. The alignment was dead on

[msatin]

Challenge #1
Some of the lite ply was quite badly warped, This is a wing tip.
Windex and weights got most, but not, all of the bend out.

[msatin]

More of the same occurred in the ply that made up the fuse.
Again Windex, and weight got a lot of the bend out.
Once everything was glued and held in place with with clamps and weights, the fuse came out quite straight.
FYI - I use ceramic tile as weights because they're heavy but spread the weight evenly (so denting in the wood), and glue does not stick to the glaze.

[msatin]

Dry fitting the fuse showed that I had to make allowances for the Cabane strut tabs.
Also some weights in the middle ensured the fuse came out straight

[msatin]

#11 - Before drilling the holes for the wing bolts, I measured the wings to be square. Despite taking my time and doing this several times, I still messed it up. 
After Frank talked me off the ledge, he provided the instructions to fix this.
#12 - Battery hatch cover. Making sure the magnets all lined up,
#13 - I used paper to make the template for the cockpit sheeting

[msatin]

14 - Gluing the motor box to firewall. Another tip from Frank I've used is to wrap the motor box with dental floss (NOT used  ) and then cover it it all in epoxy. This increases the strength.
15&16 - Framing the nose.
17 - Sheeting the nose

[msatin]

Some pics of the completed fuse.
#21-#23 are repairs and adjustments needed after the 1st sanding.
24-25 - Full dry fit

[msatin]

Starting the covering.
I prefer to use UltraCote because of it's shrinking characteristics.
#26 - I had to figure out how to cut slots in the covering where the straps were located. I preferred to the make panel as a single piece to try eliminate seams.
The backing of the Ultracote is very transparent, so used that to create a template.
1st Cut the panel for the wing section
Next I cut a large slot in the backing only, approximately where the strap was.
I used tape to make the slot size and position more accurate. Then put the backing and covering and back together, and cut the slot in the covering. When I put the covering on the wing the slots matched up with straps. Not perfect, but quite good.
If someone has a better way of doing this please let me know - I would be very interested.
#26-29 Examples of how terrible the UltraCote looks when first ironed on. Then how it looks after using the heat gun

[msatin]

I had lined up the landing gear drilled holes for the strap screws.
#30 - Although hard to see, the circles show where one screw hit the plywood, and one missed. Good thing i found this, and was able to add another piece of ply.
#31-32 - I used the method to locate the LG holes in covering as I did with the straps.

[msatin]

Starting the assembly
#33 - As I'm installing the motor and tightening the bolts, one of t-nuts pops out and is now turning freely, not allowing me to even unscrew the bolt. This is despite being super careful when installing the t-nuts and testing to make sure they were secure.
After fiddling with it I gave up, and using a Dremel cut-off wheel, cut the head off the bolt.
Once again Frank talks me off the ledge (This has become a 2nd profession of his )and provides some guidance on how to solve this. Eventually I got the t-nut back in place, and being VERY careful was finally able to get the t-nut to bite into the ply.
#34&36 - Assembly was easier than I expected, and only needed a little coaxing to get all the struts screwed into place.
#35 - Getting ready to glue the tail feathers into place, and using a level to make sure it's positioned correctly.

[Gregor77]

Looks amazing!

[GuyOReilly]

Great choice of colour.
Looking forward to seeing it fly!

[PG54]

Really like the semi- scale look
OSMW has a "Barnstormer" in the works - looks like a "Jenny"
Good luck with the maiden

[davidk]

Beautiful work, Mark... that looks great.  I really enjoy the details you provide for each step.  She's a looker.

[msatin]

Thanks for your kind words gents