Get it in the workshop and...
Hmmm, yes it is a bit of pain. OK plan B then - cut it up with a circular saw...
This was always something I was going to do at some stage, to make the aircraft more transportable and storeable (is that a word? it is now!), plus the wings are in a bit of a sorry state. There's a couple of creases where it looks like she's had a wing in the dirt at some point, some veneer had lifted, the TE was a bit bent here and there....so this'll make it easy all round.
The flap servo boxes were odd...not even tied in to the bottom skins!
Same on the ailerons..not great :
I then started removing hardware from the retract wells. Here's I have pulled about 2 pounds worth of half inch ply that is heading for the bin:
The tip panels then needed slots cutting in for a new joiner / spar system - note that the full depth ply spar only runs into the tips by about 5 inches - again not what I wanted to see, but glad I've found it :
Similarly, the centre section gets gutted a bit for joiner assembly access. Here, the spar runs full depth and width - lovely :
So the joiner then - 38mm OD aluminium. Oh yes. Quite cheap and quickly delivered by SLEC :
I chopped the joiner in half (1.5 feet per side) and chopped the phenolic outer into quarters (9 inches each). The first of the outers was then joined to a 3mm liteply back plate that'll act as a shear web in the tip panel, and the glue area was increased by using half inch triangular section balsa. The whole lot bonded with gorilla glue :
A quick test-fit in the tip panel, nice and tight :
Laid into the tip section with the spar inside to check angles:
OK, enough for now, time to get the first side glued up!