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DOWNLOADABLE PROJECT PLANS FROM THE EDITORS OF WOOD MAGAZINE http://www.woodmagazine.com

Kids will stand in line to test-fly this personality-plus biplane. Its cartoony appearance and
stout construction allow for hours of aerial enjoyment, not to mention a few hairy touch-
and-go landings. Oak and walnut provide just the right contrast throughout the design, and
you’ll find that our full-sized patterns remove the turbulence from your adventure in aircraft
construction.
Laminate the fuselage, and sand that edge flat. Now, rip the to the fuselage lamination, using spray
machine it to shape opposite edge for a 2‹" finished width. adhesive. See the full-sized patterns
1 To make the fuselage (A), cut three 2 Trim both ends of the fuselage on pages 6 and 7. (You could also
pieces of ‡"-thick stock (we used oak) lamination (A) for a 5fi" finished transfer the marks to the lamination
to 2fi" wide by 6" long. Glue and length. (We used a miter-gauge with carbon paper.)
clamp the three pieces face-to-face, extension for support.) 4 Using a Forstner or spade bit, drill
with the edges and ends flush. Later, 3 Adhere a photocopy of the full-sized a 1›" hole 1" deep in the top edge of
scrape the dried glue off one edge and fuselage Top and Side View patterns the fuselage for the cockpit.
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13/8" hole 1" deep with a
3/4" hole 1/2" deep
B
centered inside

N D

A
3/8" round-over

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1/4" hole
3/8" deep
I C
J
3/8" round-overs
K
Sand a slight taper

E
23/4"-dia. E

L 21/2"
M 17/8" hole
1/4"dowel
5/16" hole
2" long G B
5/16" hole
13/4" dia.
H
1/4" hole
EXPLODED VIEW
H
1/8" round-over 1/4" dowel
F 31/4" long G

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Bill of Materials CUTTING DIAGRAM
Finished Size
Part

Qty.
Matl.
T W L
F
A* fuselage 2‹" 2‹" 5fi" LO 1
B wings ‹" 2fi" 11" O 2 A A A
C elevator ‹" 2fi" 5Œ" O 1
D rudder ‹" 2‡" 4‹" O 1 3/4 x 31/2 x 24" Oak H
E struts ‹" 1fi" 2fi" O 2

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F* landing gear 1fi" 1fi" 2‡" LO 1 B D
G wheels ‹" 1‡" dia. W 2
H wheel covers ‹" 1¤" dia. O 2 C
B
I cowling ‡" 2‡" dia. W 1
J engine fi" 1‡" dia. W 1 1/4 x 51/2 x 24" Oak E
K engine cover fi" ‡" dia. W 1
L* propeller ‹" ‡" 6" W 1
I K
*
M nose cone fi" fl" dia. O 1
J G*
N*pilot ‡" dia. 2¤" M 1
*
*Initially cut parts marked with an * oversized.
L
Then, trim each to finished size according to
the how-to instructions. 3/4 x 51/2 x 12" Walnut
Materials Key: LO-laminated oak, O-oak,
W-walnut, M-maple. *Plane or resaw to thickness.
Supplies: ‹" dowel stock for propeller shaft
and landing gear; fl" dowel stock for the nose
cone.

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Switch bits, and drill a ‡" hole fi" Glue two pieces to the top and bottom blank. Cut the end and front view
deep centered inside the 1›" hole. of each strut to complete the making patterns to shape.
Now, drill a ‹" hole ›" deep centered of the two (E) parts. 4 Using a circle cutter in your drill
in the front end of the fuselage. 3 To form the landing gear (F), first press, or your bandsaw or scrollsaw,
5 Fasten a miter-gauge extension to laminate two ‡×1fi×3" pieces cut the 1‡"-diameter wheels (G) to
your miter gauge, and mount a ‹" together. Next, from this lamination, shape from ‹" walnut stock. If you
dado blade to your tablesaw. Using cut a piece that measures 2‡" long. cut the wheels to shape with a bandsaw
your miter-gauge extension for support, Now, adhere the full-sized Front View or scrollsaw, you’ll need to drill a ‹"
cut a 2fi" rabbet ‹" deep across the and Side patterns to this landing-gear hole centered in each. If you use a
bottom edge of the fuselage for the blank. Drill a ˇ" hole through the circle cutter, the ‹" pilot bit will form
lower wing.
6 Remove the miter gauge and switch
to a ‹" dado blade. Raise the blade 1" 13/8" hole 1" deep with
above the table surface. Now, adjust a 3/4" hole 1/2" deep 3/4"
1" 3/4"
the fence and blade according to the centered inside 3/4"
elevator notch location on the pattern.
With the fuselage blank standing on 51/2"
end, use a wide pushstick to cut the 1/4"
13/4"
elevator notch as shown bottom left.
Adjust the fence and cut the rudder
3/4"
notch the same way.
7 Tape a scrap piece of ‹"-thick stock 21/4"
in the lower-wing rabbet to hold the
piece level. Then, bandsaw the fuselage
A
tail section to shape. To do this, cut Elevator
along the Top View pattern lines first, 1/4" notch
adhere the waste pieces to the fuselage
with double-faced tape, and then
bandsaw along the Side View pattern
1/4" hole 21/4" 21/2" FUSELAGE
3/8" deep
lines. Remove the waste pieces, and BLOCK
sand the fuselage smooth.
8 Rout ›" round-overs along the edges
of the fuselage where shown in the
Exploded View drawing. When CUTTING THE ELEVATOR NOTCH IN THE FUSELAGE
routing, position the pilot of the router
bit to guide along the surface adjacent
to the cockpit hole. Otherwise, if you
run along the same surface, the bit’s
pilot will hit the cockpit hole and rout
unevenly. Remove the scrap spacer
from the lower-wing rabbet.

Transfer the patterns, and


cut more parts to shape
1 Transfer the full-sized patterns for
the upper and lower wings (B), elevator Fence
(C), rudder (D), and struts (E) to ‹"
stock. (You’ll find these patterns in
the pattern insert in the center of the
magazine.) Using a bandsaw or a
scrollsaw, cut the pieces. Note that the Pushstick
upper and lower wings are the same
size and shape except for the cockpit
cut-out in the upper wing.
2 Cut the eight wedge-shaped pieces ‹" dado
for the strut’s, top and bottom. blade

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ROUTING THE COWLING USING A V-NOTCH FENCE

Auxiliary fence
with V-notch To sand consistent
round-overs on wheels,
run a bolt the same
diameter as the axle hole through
a washer and the wheel’s axle hole.
Slide on another washer and tighten
the assembly with a nut. Now, chuck
the bolt in your drill press and sand
the edges of the wheels with a
sanding block.

the hole. Now, sand a ¤" round-over 4 Transfer the full-sized propeller hole in the engine with the one in the
along the outside edges of both wheels. pattern (L) to ‹" walnut stock. Drill fuselage. Next, glue the cowling (I) in
To do this, see the Tip on sanding the ˇ" hole in the center of the place around the engine. Now, insert
consistent round-overs located on this propeller, and then cut the propeller the propeller shaft and attached nose
page at far right. It’s one you’ll be able to shape. Sand opposite edges on each cone through the propeller, and glue
to use in numerous other woodworking propeller edge for a more authentic the end of the propeller shaft into the
applications. look. airplane body. Leave just enough of a
5 Cut the wheel covers (H) to shape 5 Cut a ‹" dowel to 2" long for the gap for the propeller to spin freely.
from ‹" stock. Sand the wheel covers propeller shaft. Then, cut a piece of 3 Glue the rudder and elevator to the
to the shape shown on the Parts View fl" dowel stock to fi" long for the airplane’s chubby fuselage.
pattern. nose cone (M). Use a handscrew clamp 4 Glue one end of the landing gear
6 Center and glue a wheel cover (H) to hold the fl" dowel piece steady, and axle dowel into one of the wheels.
on each wheel (G). drill a ‹" hole ‹" deep centered in Slide the dowel through the landing
one end of it. Glue the ‹" dowel into gear and glue the other wheel in place.
Make a mighty engine the hole in the fl''-dowel nose cone. Finally, glue the pilot in the cockpit,
1 Mark the inside and outside diameter Using the ‹" piece of dowel as a and apply a clear finish (we used Deft
for the cowling (I) on a piece of ‡"- handle, sand the nose cone to the shape aerosol lacquer). ¿
thick walnut. (See the Exploded View shown in the pattern insert.
drawing.) Cut the outside diameter to 6 To make the pilot, use a toy person
shape, and then rout a ›" round-over or a 2¤" length of ‡" dowel, with one
along the outside edge. To do this end sanded to the dome shape shown
safely, we used a table-mounted router in the pattern insert. Using acrylic
and an auxiliary fence with a V-notch paints or felt markers, draw a face and Produced by: Marlen Kemmet
Project Design: Richard Gard
cut in it as shown above. Cut the inside helmet on the pilot (again, refer to the Illustrations: Roxanne LeMoine, Troy Doolittle
diameter. pattern insert). Graphic Design: Jamie Downing
2 Transfer the full-sized engine pattern ©COPYRIGHT MEREDITH CORPORATION 1997
(J) onto fi" stock, and cut the engine Now, for the final assembly
to shape. 1 Glue the lower wing (B) to the The purchase of these plans does not
3 Use a compass to scribe a ‡"- fuselage (A). Then, glue the struts (E) transfer any copyright or other ownership
interest in the plans, the design, or the
diameter circle on a piece of fi" stock and top wing (B) in place. Center and finished project to the buyer. Buyer may
for the engine cover (K). Drill a ‹" glue the landing gear (F) to the bottom neither reproduce the plans for sale nor
hole in the center of the marked circle, surface of the lower wing. offer for sale any copies of the finished
and then bandsaw or scrollsaw the 2 Center and glue the engine to the project.
engine cover to shape. front of the fuselage, aligning the ‹"

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To ensure full-sized patterns are correct size, your
printer should be set to print at 100% (not fit to page).
Measure full-sized patterns to verify size.

1/4" elevator notch


1" deep

G
A
FUSELAGE TOP VIEW
1/4" hole
H

3/4 " hole 1/2" deep


1/4" hole
3/8" deep
13/8" hole 1" deep
Wheel and wheel
cover side view

1/4" rudder notch


A
1" deep N
1/4"
FUSELAGE SIDE VIEW HEAD
hole
3/8" deep

21/2" rabbet 1/4" deep 3/4" dowel


21/8" long

PROPELLER
SHAFT
1/4" hole
M 1/4" deep
H

1/4"
WHEEL COVER SIDE VIEW
dowel
2" long 1/4" hole

J
1 /4" hole
ENGINE

ENGINE COVER SIDE VIEW E

STRUT SIDE VIEW

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B
WINGS

5/16" hole

C Cut out for


upper wing
ELEVATOR L

centerline

PROPELLER
F
LANDING GEAR
SIDE VIEW

D 5/16" hole
RUDDER E

F
LANDING GEAR FRONT VIEW
STRUT
TOP VIEW

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