ZAGI 400 ELECTRIC Assembly Manual - page 4
Optional Procedure
A smooth finish can be obtained using light weight spackling with a minor weight penalty. Apply
the spackling to the 1# foam only and not on the EPP leading edge. Apply a thin coat of lightweight
spackling with a 4 inch wide squeegee. Let the spackling dry. Sand to a smooth finish with 320 grit
sandpaper.
Vacuum the dust from the cores, beds and the work bench. Lay the wing in the beds top-side up. Apply a light
coat of 3M Super 77 spray adhesive to cover the top of the entire wing. Allow the adhesive spray to dry at
least 30 minutes. Repeat this procedure on the other side.
The fiber tape schedule described in Figure 3 is intended for aerobatics and thermal applications. If
the tasks for the Zagi-400 will include high-speed dives, the fiber tape must be increased to three
side-by-side strips instead of only one or use 2” fiber tape. The two-inch tape I used increased the
flying weight by ½ ounce.
(See Figure 3) Lay the wing top-side up in the bottom beds. Apply a strip of 3/4’’ fiber filament tape along
the trailing edge between the wing tip and the prop cutout. Apply another strip to the trailing edge to extend to
the opposite leading edge. Apply two spanwise strips of tape at the motor tray cutout extending to the leading
edge on both sides. Apply another two spanwise strips of 3/4’’ fiber tape in the center of the wing 4’’ from
the motor tray cutout. Apply two strips of fiber tape diagonally from the nose to the outboard tip of the trailing
edge. Lay the wing bottom-side up in the top beds and repeat the same taping procedure on the bottom side.
page 4
2 1/2’’
5’’
Figure 2
12”
Layout the bottom beds on a flat surface. Tape them together. Repeat for top beds. Align the cores together
on the bottom bed. Spray the root end of the wing cores with #77 spray adhesive. Put a piece of clear wrap
or wax paper between the beds and the cores to prevent sticking. Let the adhesive dry for 10 minutes. Put the
wing cores together using beds as a jig.
(See Figure 2) Measure 12” from the nose along the center line and make a mark. Use a square to measure
2 1/2’’ on both sides of the center line. Mark the 5” line and make two lines parallel to the center line from the
ends of the line to the trailing edge (TE). Cut along the lines and remove the foam.