Great Planes Giles G-202 46 Kit - GPMA0238 - Manual (Page 12)

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3. Align the end of each spar doubler with the inboard
end of one of the 1/8 x 1/2" x 30" balsa spars. Glue the
spar doublers to the spars. From this point forward we refer
to this combination as a spar.
The construction of these wings is engineered specifically
to provide a perfectly straight and true wing panel with
minimum effort on your part. To do so, the building
sequence and pieces are quite different from what you may
be accustomed to. Be sure to read all steps carefully and
pay particular attention to instructions of when and where to
apply adhesives.
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1. Tape the right wing plan to the building board, and
cover the wing drawing with Great Planes Plan Protector.
Remember, we are building the right wing upside-down
over the right wing bottom view.
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2. Position the top spar on top of the plan with the
spar doubler visible, aligning the end of the spar doubler
with the “ALIGN BASS SPAR DOUBLER HERE” marks
on the plan. The spar will overhang both R-1 and R-11. Do
not cut them at this time. Pin them in place as shown in the
photo. Note: The pins are offset the aft side to leave space
for the main web.
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3. Carefully punch out the four die-cut 3/32" balsa
webs and the die-cut 3/32" balsa wing ribs. Sand the
edges slightly to remove any die-cutting irregularities. Be
careful not to alter the shapes or angles of any of the pieces.
Note: Do not glue until instructed to do so.
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4. Select the die-cut 3/32" balsa rib R-3, main web,
and aileron web (with support jig attached). Slide R-3 into
its slots in the main web and the aileron web. Align the
main web, centering it on the spars and aligning the notch
on the top of the main web with the spar doubler. Align the
aileron web in position on the plans with the root end flush
with the wing centerline. Pin the root end of the aileron web
in place as shown.
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5. Position R-10 in its slots to lock the webs in place.
Insert all of the remaining ribs except R-2A into their
locations. Note: If you happen to break one of the ribs
during installation, simply take it out of the wing, position
the pieces together and glue with thin CA. Allow to dry and
reinstall.
Designer’s Note: Occasionally outside forces such as
humidity and dramatic temperature changes can result in
slight inaccuracies in the dimensions of printed plans. One
of the many advantages of a fully interlocking wing such as
this one is that exact alignment over a printed plan is not
necessary to ensure a straight wing. If the ribs do not align
perfectly over the plans, don’t worry! As long as the spar
doubler is aligned as shown and the aileron web is aligned
with the centerline of the wing, the wing will be true.
IMPORTANT NOTE: The following instructions explain
how to build the wing directly over the plans. We’ll start
by building the right wing panel upside-down over the
right wing plan so your progress matches the photos.
Build the Wing Panels
12