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Taboo GT - Foam Tails Installation

1. Foam tails before installation as they come with the kit.
2. Cover the center of the vertical tail with masking tape. Mark the location of the cuts on the tape. Use the tailboom end to determine the exact distance between the cuts. The cutout must stop 5-8mm before the spar.
3. Make two parallel cuts using a band saw or X-acto knife. The cuts must be slightly inside the marks to account for the round shape of the tailboom; do not make the cutout too wide, otherwise you will have gaps that will have to be filled with epoxy-microballoons.
4. Remove the cutout piece by carefully cutting it with X-acto knife. Make a sanding tool from a dowel or a brass tube; glue a piece of sandpaper over it. The dowel must be slightly smaller than the tailboom diameter. A 5/16" brass tube and 150 grit sandpaper are shown here and were used sucessfully for the job.
5. Either by hand or by using a drill press set to the lowest speed, make the shape the inside of the cutout cylindrical, and enlarge the cutout to fit snugly over the tailboom.
6. You can trim the kevlar fibers around the cutout or leave them on the skins - they will serve as a reinforcement for the bond between the fin and the tailboom.
7. Scrape the tailboom where it will contact the vertical tail. Slide the tail over the tailboom to check the fit.
8. Attach the wing to the fuselage, position it on a table up side down - this will give you a good reference line for aligning the vertical tail. Use thin laminating epoxy or medium foam safe CA to attach the fin. Smear the attachment area with the glue and carefully slide the fin onto the boom, all the while making sure that the tail is square to the table.
9. Make a fillet of glue around the entire joint line to make sure that the skin is attached both to the foam core and to the tailboom.
10. Cover the center of the stab with a piece of masking tape. Mark the centerline on the tape. Mark locations of the attachment bolt holes. The distance between the holes is 20mm.
11. Using a toothed brass tube or an X-acto knife, make oversized holes through the top skin and the foam. Keep the bottom skin uncut. Dig out the foam inside the tunnels. The size of the top skin holes must allow the head of the attachment bolt to go through. This will allow you to sink the bolts into the tail.
12. Using a small steel wire with an L-bend on one end, set the drill press to a low speed and pulverize the foam around the holes to create a cavity slightly larger than the size of the cut in the skin. The hard point must go under the skin on all sides of the bolt hole, otherwise there will be nearly no strength in the joint.
13. Mix 5-10 minute epoxy and microballoons. Fill the cavities completely with the mixture. Let the epoxy set completely before continuing.
14. Using a large enough drill bit, make a clean sink for the bolt head in the hardened epoxy-microballoon hardpoint. The indentation must be only as deep as the bolt head. Do not weaken the hardpoint more than necessary.
15. Drill the bolt hole through the bolt sink. The bolt head must be level or slightly below the top skin when you are done.
16. Attach the stab mount to the stab. Scape the surface of the tailboom where the stab mount will be glued.
17. Using medium CA attach the stab mount to the boom making sure that the stab is square to the fin. Use the same technique as for aligning the vertical tail if necessary (put the fuselage with the wing attached on the table, up side down).
18. Control horn installation is exactly the same as on balsa tails. Use X-acto knife to make a slit for the control horn. Keep the opposite skin uncut.
19. Glue the control horn with foam safe CA. Insert the wire end into the control horn. Apply a drop of medium CA, then slide a small piece of heat shrink tubing over the wire. Shrink the tubing with a soldering iron.
20. Create a supporting web between the tailboom and the pushrod housing tube. Use a tiny piece of balsa and CA. Make sure not to get any thin CA inside the teflon housing, use medium CA.
21. Rudder control hookup is done.
22. Elevator control hookup is also identical to the balsa tails. Use foam safe CA to attach the control horns.
23. Elevator control hookup is done.
24. Foam tails installed and controls attached. Ready to rock and roll...

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