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Installing the RDS pockets is fairly easy with the right tools and materials. Work time is short, cure time depends on the epoxy used.
Use the shucks to hold the wing during work and cure time. Use weights to hold the pocket in place. Use the pocket protector to protect the opening size while weighted.
Avoid damage the flaperon hinge, and place the pockets in the exact location.
#11 Hobby knife with a fresh blade
Other cutting knives as you might have, or wire, to cut the foam you are about to hog out (see photo in procedure below)
Dental pick or similar
Air disappearing marker pen (optional)
Weight bags or bars
Microballoons for thickening
2 mil polyethylene plastic or similar, to prevent
surfaces from bonding or getting epoxy on them
Unless you have a stand for the wing to rest on, perform each of these procedures one wing side at a time.
To know where the pockets go, you must know where the servo bays are. It is best if you have the servo bays cut, and all will go in the right place if you use the RDS template.
With the RDS template as guide and using the air
disappearing marker pen, mark the corners for the wiper pockets.
Connect the dots to show the exact outline.
At the hinge, make a dark mark that will show
through to the other side.
Mark the flaperon foam where the wiper pocket
Carefully fold the flaperon back. If the hinge
needs to be loosened, carefully work the flaperon back and forth. We need
the flaperon to lay flat back against the bottom of the wing without delaminating
Mark the other side of the flaperon using the actual pockets as templates.
A good variety of hobby knives makes this job easy. All we're doing
is slicing and then picking out the foam in this area. Any razor tools
you have, if small enough, will likely work.
Do not cut the Kevlar skin. Only the foam...
An assortment of tools useful for cutting the foam without cutting the skin
From the flaperon face, slice the foam along the
lines. Cut as deep as the pocket goes.
Slice the foam where it bonds to the Kevlar skin,
both top and bottom.
With a dental pick or similar tool, hog out the
foam for the pockets. If you have sliced the foam cleanly, the foam will
lift out easily and all surfaces will be smooth.
To prevent bursting of the pocket sides in crashes and other extreme loads, wrap the perimeter of the pocket, except for the front, in 1/2" wide lightweight fiberglass (included in our RDS kit). Attach the fiberglass with 3M77 adhesive.
The fiberglass comes on a wax paper carrier. The good trick is to peel 1/2" of the wax paper, spray the fiberglass with 3M77, and attach the glass around the sides. Then peel the wax paper, and finish by wrapping the overlaps around the sides of the pocket.
Epoxy and Microballoons is the material of choice for this task, as there should be a tiny bit of filling to do all around the pocket. The pocket protector stays in the pocket until the epoxy cures. Polyethylene plastic protects the wing and flaperon from bonding to each other. And heavy weights are gently set onto the curing pocket. You want a smooth surface and no bulges to the skin.
Dry fit the RDS wiper pocket to ensure that it
fits without bulging the skin.
If needed sand the outside of the pocket to fit.
Mix a few grams of epoxy, and thicken it to peanut
butter consistency with microballoons. Save a small amount unthickened
for wiping the fiberglass wrap on the pockets.
Lay a piece of polyethylene plastic sheet in between
the flaperon and the bottom of the wing.
Into the hole in the foam, spread the epoxy mixture
so there is a thin layer all around the opening. You want just the right
amount of epoxy to avoid both voids and bulges.
Wipe the fiberglass around the wiper pocket with unthickened epoxy, and tamp the glass with paper towel to remove excess epoxy
Insert the wiper pocket with pocket protector.
Remove any excess epoxy without getting any in
the wiper pocket.
Place a small sheet of polyethylene plastic on
top of the bonding area, then place an oversize piece of 1/16" balsa
on top to concentrate flattening weights in the area.
Weigh the assembly down to make the RDS installation
flat and clean.
Allow the epoxy to cure.