I got a canopy for the Sig 4 Star fr om Sig Mfg., USA

The original is a built-up Balsamodel covered with heat-shrink covering

I'm trying to do it with a Balsa-sheeted Foam wing, and a Corro fuse and tail

Also, the original uses a single aileron Standard Servo, I'm going with 2 X 19 gm MG

Specs:

Wingspan   59.75 in   1518 mm
Wing Area   604 sq in   39 dm²
Length   47 in   1194 mm
Flying Weight   4.75 lb   2150 g
Wing Loading   18 oz/sq ft   55 g/dm²
Radio Required   4 Channel, 4 Servos (not included)
Engine Required
2-Stroke .40 - .45 cu in (6.5 - 7.5 cc)
4-Stroke .40 - .50 cu in (6.5 - 8.2 cc)

The weight of 2150 gm is a challenge. Although I'm sure it will fly well even at 2500 gm

@sanjayrai55,
Two strips of double sided sticky tape, and adhesion at LE and TE?

Wish I had thought of that.

Such an elegant solution.

Never got around to building a balsa skin foam core wing, after failed attempts in early 80s.
Good to learn from a real innovator...

Kind words Iyer sir

However, the actual process was:

I first glued a 1.5 mm balsa strip to each face with 5 min epoxy
Then I sanded the faces as carefully as I could to get them square and flat
Next, joined them with regular Araldite
Finally, put a 5" wide "patta" of medium glass fibre, saturated with regular Araldite

Hope it doesn't do namaste while doing a loop or roll

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I meant gluing the skin to the core.
Not the centre joint   

The balsa skin is glued to the foam core using regular Fevicol. The cut-outs are placed on top, with heavy weights, and allowed to dry for 24 hours

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Gives a very strong and reliable bond

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BTW, this is my first time with this kind of build too. 😉

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Unsurprisingly, this thread has 186 views, and comment only from one - Iyer sir

My last build thread, Ugly Stik had 286 views and a comment from ....... Iyer Sir!


A year ago, my Fleet Bipe Log had 12300 views and 77 replies, from 18 different people

What has changed?

In fact, I haven't posted the log of my last build, a full sized Das Ugly Stik built in Corro to the original Phil Kraft plans. Just not worth the effort

Thats a clean build, I had seen such balsa wood in RCbazaar. I shall attempt this build technique .

@Sanjay sir, the reason for less traffic may be the Quad effect. More people are getting into quads, with major institutions and manufacturers promoting quad racing events only, and advertising such accessories.

Pure flying is taking a back seat.

In Whatsapp groups people mostly talk Drones , rarely talk planes, and very very rare helis .

I was wondering one thing, does this wing not require any spars ?

If it requires spars , how are you gonna put it in now ?

Dear Sanjay sir,
I do agree to your opinions that having good no. of views and not any comment/appreciation is a little disheartening...Though I personally  being a scratch builder, know the worth of such build logs. I have earlier also seen your build logs in corro and have loved them. My personal comment would be to keep going on with your build logs. I have seen people reacting to build logs on RC universe forum. Its totally different there. Mostly new people are into drones and traditional balsa kit building has been reduced due to foam building...But maybe in coming time the young generation of this forum will also evolve to appreciate such efforts when they understand the difficulties and joy of a balsa scratch building.

Best Regards,
Khushahal

@sanjayrai55,
@glidiator,

Welcome to the club!

Do you remember how you scolded me for putting up my Indore Bipe for sale due to frustration at lack of response?

Remember. You and flyingboxcar are the only ones getting responses from abroad.

How did I feel at the poor response to the 1 min /30 sec challenge, despite prize money offer?
How did Glidiator feel when he doubled the prize, and still no entries?
How did he feel when no entries for his rubber power workshop?

Your build logs need to be on RCGROUPS
You won’t believe the international response you’ll get.
From real experts and world champions.
I know because I’ve been there.
Time you did!

No spars. Actually if you observe, we have a 1.5 mm X 450 mm cross-section of balsa doing the job of the spar!

Similarly, no dihedral brace

Pnkyjs, Khushahal, Iyer sir: very thought provoking comments

But, the reason I post my builds on RCI is with the intention of other aeromodellers getting encouraged to build. And corro is a wonderful material to build with, very economical and durable. With a bit of effort, Corro models don't have to be either ugly nor heavy

I'm not getting any younger, and guess I have only a few years more of building. So, I will continue to build and post on RCI. If a few get encouraged to try, my day will be made

If people participate and make the thread more interactive, it encourages others to read, and also participate; this then is a knowledge exchange

After some long months, today got the opportunity to visit my RCI in relax.
And what i see, one more detailed, beautiful build from Sanjay Rai sir.

Sir keep your good work.

Thanks Manoj! 

@sanjayrai55,

Sirji, a small suggestion.
Don’t post the pics of the entire build in one post.
Post the pics one at a time, as the build progresses.
Giving viewers a chance to respond at the intermediate stages...
Regards

Such builds are treat to eyes..... and tonns of ideas  & motivation to make models.

Nicely built too many techniques used... Hot wiring, balsa sheeting, Wing joining without spar to name a few.
I am one of the prevailed ones to see it in reality.

regds
Saurabh

Noted, sir.But needs more time

Thanks Saurabh. Now you have no excuse not to build a scale corro model, especially as you are flying a 1/6 scale Corro Piper Cub

Rai sir after long time very excellent build by you specially balsa,coro and foam


Regards
Gaurang

Thank you Gaurang-bhai 

I made a servo tray. Normally I just glue 2 rails and screw the servos down on them. But this time I decided to go with the tray, so I could slide it forward and aft to set the CG



The white servo (19 gm MG) is for throttle, others are rudder/tail wheel and elevator

Assembling the fuse in the Jig

Cut out slots and matching plugs to locate the tail parts accurately

Love your jig.
If I had one, my fuselages would be square too
Instead of like Bananas  
Regards

Iyer sir, make a Jig. It's easy 

Push rods and formers

Turtle deck from 1.5 mm balsa and some 3 mm formers and longerons

Test fit

Lovely build! And the pilot has a moustache!

  Hi Girish

Covering of wing started

Beautiful build sir! 
Following the thread actively! 

Thanks Prabal

Jig idea is awesom. Will use in another way for my composite models. Thanks for sharing

You are welcome

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When is it supposed to be in the air sir??

Soon   I'm in no hurry

Sir, is the tailplane stiff enough by itself?
Or have you inserted a skewer/ CF rod in the flute?

Pertinent point, Iyer sir

I have had flutter issues before too

What I do ( where feasible) is use 3 mm corro doubled, two sheets glued together with cyano

This renders it stiff enough, but finally will only know in the air. Worked OK on 40 size models till now

The 3 mm corro (actually 2.5 mm) flutes don't have enough room to insert a skewer or sizable CF Rod/tube. The maximum diameter admitted will be < 2 mm

Dear KK Iyer ji,

I used 10mmx5mm thick wooden reaper instead of balsa wood running from nose to tail end in fuselage. It works good.

Dear Sanjayrai ji,

How do you fix the front wheel axle? In the first set of wooden supports or with the engine mount?

I'm not too sure what your question means, but will try anyway:

The engine mount/firewall will only be used for a nose wheel, with a tricycle landing gear

This is a taildragger. The main LG is bolted onto a 8 mm ply plate, which abuts the front former, and is glued to the former and the sides. Further reinforcement is given by two 10 mm pieces of balsa

Just a little cramped, but everything did fit OK

Complete

Very fine! All the best for the maiden

Thanks Girish

wow.. simply elegant,,

Thank you. Hope it flies well

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Had a very successful maiden

The model flew straight off the runway, with NO trims required!

 The 4 star turned out really fantastic. Needed no trims at all.

Flies absolutely true, smooth and stable. Highly responsive to the controls

Probably one of the best Flying models I've ever built

Did stretch it's legs a fair bit

Loops, rolls, inverted, spin, horizontal loops - the works 

Sir ,
looks factory made. Absolute craftsmanship.
flies great too.

Thanks Manoj. It was really a pleasure​ to fly

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Beautiful build Sanjayji.....how is the Jig made are the stoppers pinned down .

Thanks buddy. The jig uses thumb screws to hold down in place

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Lovely Sir,  The model flies very well.... and guess you indeed took it to the limits....... The expression on the face of the pilot says a lot about it....

Don’t know how I missed seeing the videos for 3 entire days.

But I remember you started this thread with “I got a canopy...”

What a difference the canopy and pilot make, even to an otherwise professionally finished model.

All I can say is “Sirji, abhi aap me kafi dum baki hai”

An inspiration for many (including me) to talk less and build more!

Regards

Hah ha! Thanks so much Shobhit!

Thanks so much Iyer sir

The Canopy was affordable ( about $ 6~7) so I got it and the printed plans (about $ 5) shipped to my sister-in-law's residence in USA, and my wife had gone there and carried for me

Since even the local shipping is expensive ( when you convert to IRS ) I ordered more stuff - the turtle deck, cowl and canopy of the Sig Kougar! That's going to be my next build, and the first I will be attempting without plans! (no plans available for the Kougar)