From: "Capps Family" <capps@mediaone.net>
Subject: COZY: Winglet Attachment
Date: Sun, 16 Jan 2000 11:47:57 -0600

To All,

Here is a method I thought needed included in our archives.  This seems to
be a very interesting procedure for measuring, cutting and attachment of the
(winglets).

Larry

Larry A. Capps
Cozy MKIV 829 (chaps 4-8)
Naperville, IL
capps@mediaone.net

=
WINGLET ATTACHMENT:

<<  "Long-EZ construction:  Measure with a Micrometer, mark with a
 Magic Marker, cut with a Chainsaw". >>

Ken,
Exactly! <LOL>

That is how I felt about the plans-depicted winglet attachment procedure.

The first problem: Measuring within .05", I did not like the variability
of  measurement of the winglet itself, i.e.,  lay-up overlaps on the
winglet, hot
wire errors, Determining the exact centerline of the airfoil by eyeball,
etc...........waaaaaaaa.

What I did: Instead of measuring with my winglet, I used the winglet base
hotwire template to determine the winglet placement exactly and then scribed
the winglet shape from the template onto the wing.

The second problem: The plans specify a "razor saw" to cut the wingtip to
match the winglet.  Maybe I am inept, but I could not get a symmetrical cut
on both the lower and upper skins at the same time while operating the saw.
(I made some practice cuts in the area to be discarded.)

What I did: First I scribed the winglet shape on the upper AND lower wing
skins using the winglet hot wire template.  Then I used a rotary cutter on
my
trusty Dremel tool and cut both scribed marks through the skins.  Then I
used
the saw to cut the foam and shear web.

I repeated the process cutting the wing shape into the winglet using the
wingtip hotwire template and when I placed the winglet on the wing,
everything matched-up and was aligned.  I couldn't believe it! Maybe I just
got lucky, but I think this procedure was as idiot resistant as I could make
it, (which in my case..............).

Well anyway,
It worked for me.
Bruce Vinnola
ERacer#109