AS5048/46 Outer Wings

Along with the four 1.5"x 4'x 9' sheets of Trymer for the wings, I purchased two blocks 6" x 8" x 48" for the wing tips. The outlines were drawn in TurboCad and plotted out at the local reprographic shop. There was a right, left, top, and bottom shapes drawn. They were glued onto a 1/4" sheet of masonite, cut out, and sanded to final shape.

I drilled some small holes into the sanding template for some 3" coarse drywall screws. Do not put them in with a power driver, They will strip out the foam very easily. All you want is for the screws to just hold the templates from moving. Draw a center line on two opposite sides. Attach the two templates. I used a small saw to rough cut to the template, then finished with the belt sander. The top and bottom templates were attached next. Follow the same procedure.

After both wing tips were rough sanded to shape. I used a large block sander with 60 grit sandpaper to round the corners. I switched to some 240 sandpaper to put a finished surface to the tips. Total time to this point 2 hrs. Now it is time to glass them and mount the wing tip light bracket.

After the wings are glassed these tips will be attached and glassed to the wings.