WattAge F-86 Sabre EDF Instructions For Final Assembly - page 11
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Test-fit the fuselage sides together with the ducted fan
assembly in place. They should fit together with few or no
gaps between the two, and the outside edges of each side
should line up evenly.
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If the fuselage sides don't fit together properly, carefully
remove any irregularities in the foam using 220 grit sandpaper
with a sanding block.
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Mix a generous amount of 5 minute epoxy and apply a thin layer to the gluing surfaces on both fuselage sides. Apply
a couple of dabs to the bottom of the ducted fan shroud, too.
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Fit the fuselage sides and ducted fan assembly back together and realign them. Remove any excess epoxy using a
paper towel and rubbing alcohol, and hold the sides together until the epoxy sets up.
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We used a couple of large, wide rubber bands to hold the fuselage sides together. If put over the fuselage sides
carefully, they won't damage the foam. We don't suggest using pieces of masking tape because when removed, the tape
will pull away the paint.
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After the epoxy has fully cured, cut a couple of 3/4" square pieces of clear decal material from the decal sheet. Apply
these pieces over the front and back of the channel to hold the motor wires in place. Doing this will keep the wires from
drooping into the intake duct.
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We actually used one long strip of clear tape to do this but it's difficult and takes some time due to the limited amount
of space inside the intake duct. It isn't absolutely necessary, either. If you want a completely sealed intake duct though,
give it a try.
Step 2: Joining the Fuselage Sides
IMPORTANT
Hold the fuselage sides firmly together around the fan assembly. While holding the sides together, carefully spin the
impeller using your finger. The impeller should spin freely and not touch the sides of the shroud. If the impeller does touch
the sides of the should, the shroud may be distorted. If this is the case release some pressure on the fuselage sides and
recheck the impeller.
Before gluing the fuselage sides together in the next procedure, please realize that the ducted fan assembly must be
tack glued into place so it does turn inside the fuselage. Only tack glue the bottom of the ducted fan assembly to the
fuselage sides so it can be easily removed in the future if it needs to be. If you glue the ducted fan assembly into place
from the top (or use a lot of glue), it may be impossible to remove it if you ever need to!
If you haven't already broken in and tested the motor, we strongly suggest doing that now before installing the ducted
fan assembly into the fuselage. Once the ducted fan assembly is installed, it cannot be removed without cutting a
hatch in the bottom of the fuselage.
Step 3: Installing the Radio Tray
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Using a pair of scissors, cut away the excess plastic from around the edge of the radio tray, making sure to leave a 1/8"
lip to use as a mounting surface.