Great Planes Giles G-202 46 Kit - GPMA0238 - Manual (Page 20)

line around the control horn. Remove the screws and the
control horn. Using a hobby knife, poke 12 pin holes in the
top sheeting within the rectangle you drew, then apply a
generous amount of thin CA. Allow the CA to cure,
hardening the balsa, then sand the sheeting smooth. Note:
Use enough CA to have some enter the screw holes;
however, do not use so much that you fill the holes with CA.
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8. Complete steps 1-7 for the left wing panel.
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1. Place one die-cut 1/8" ply former F-1 on the building
board, punch marks facing up. Glue the second F-1 to the
first with 30-minute epoxy, again with the punch marks
facing up. Make sure the edges all the way around are
aligned. Wipe away excess epoxy before it cures. From
now on this assembly will be referred to as the firewall.
Note: If the formers are warped, simply clamping them
together may not “cancel out” the warps. It is best to clamp
the formers to a table or a flat board until the epoxy cures.
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2. Using a ruler or other straightedge and a pen, draw a
line horizontally across the firewall from the left edge punch
mark to the right edge punch mark. Draw a line vertically
from the top punch mark to the bottom punch mark. The
intersection of these two lines is the center of the engine mount.
Note: This location is offset for the right thrust built into the
model so that the spinner will still align with the center of
the cowl.
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3. Assuming you are using the included Great Planes
adjustable .60 - 1.20 engine mount, drill the four 7/32"
engine mount holes at the punch marks as shown in the
photo. Drill the two 1/4" fuel line holes and the 3/16" throttle
exit hole as shown in the photo. Note: This throttle exit
placement works for the recommended 2-stroke engines,
clearing the exhaust, as well as 4-stroke engines with the
carburetor rotated 180°. If you are using a different mount,
install it per its instructions, centered on the centerlines you
drew in step 1.
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4. Drill two 1/16" holes through the punch marks in
former F-3. Drill four 3/16" holes through the punch marks
in formers F-5 and F-6. Hint: Place the formers on a scrap
piece of wood and press down as you drill the hole so the
former does not split when drilled.
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5. Press four supplied 8-32 blind nuts into the holes on
the back of the firewall. Gently tap the blind nuts with a
hammer to fully seat them into the firewall. Add a few drops
of thin CA around the blind nuts to secure them.
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6. Lay the two fuselage sides next to each other as
shown in the photo. Glue one die-cut 1/8" ply fuse doubler
to each fuse side, aligned with the wing saddle and the tab.
Label the insides as LEFT and RIGHT. It is important that
you have the fuselage sides in a mirrored position to insure
that you build a left and a right side. Hint: To help you
recognize left from right fuse sides, set the sides upright
and pretend you are in the cockpit.
Assemble the Fuselage
Formers & Sides
BUILD THE FUSELAGE
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