Sonicdad Sonic silhouette User manual

Project #40 Page 1/25

FPG: Sonic Silhouette

Foam Plate Glider: Sonic Silhouette

Ritchie Kinmont

About this project:

The Foam Plate Glider Sonic Silhouette is the first in a series of flying glider projects

made from foam plates. This project is designed as a hand thrown glider, launched from

the ground, or launch from an elevated location for longer flights. Although fun for all

ages, younger children may require help hand-launching this glider.

Get some Sonic

glider time in with

this awesome

building project!

You’ll be a glider

pilot in no time!

Rev:03/15/13

What’s it made of?

The Sonic Silhouette is made from foam plates, a plastic drinking straw, and full-sheet

printer labels for the airframe. Metal washers provide the nose weight, and craft foam

adds a soft tip.

Metal washers

Foam plates

Full sheet ink

jet labels

Foam craft sheet

Project #40 Page 2/25

FPG: Sonic Silhouette

Rev:03/15/13

Drinking straws

Project Construction

Check out my way cool Sonic Dad

gauges for project difficulty,

time, and cost. Cost of this

project depends on how many

items you have on hand. If you

purchase all items new, cost will be

higher than the approximate cost

shown.

LEVEL 4 $6.00

1.0 HRS

SHOPPING LIST

Quantity Item needed Where to find it See Figure

1 pkg

10.25” diameter disposable foam plates (Home

Store brand

from Dollar Tree stores recommended SKU#16449)

Dollar Tree, Dollartree.com

online store

Page 2,

A, C

1 pkg

Avery

full sheet ink-jet printer labels #48165

Wal

-Mart, office supply store

Page 2, B, C

1 pkg

#10 size SAE flat washer

Wal

-Mart, home improvement store, hardware store

Page 2, NN

1 sheet

2mm craft foam sheet (black or

the color of your choice)

Wal

-Mart, craft store

Page 2, OO, PP, QQ

1 pkg

Regular plastic drinking straws (1/4” diameter)

Wal

-Mart, craft store

Page 2, K, L

SUPPLIES AND TOOLS NEEDED

Item needed Where to find it

Sharp scissors

Discount retail store, home improvement store

Low

temp hot glue gun

Discount retail store, home improvement store, craft store

Metal ruler or straight edge

Discount retail store, home improvement store, craft store

-acto knife with sharp blades

Discount retail store, home improvement store, craft store

Gule

stick

Discount retail store, craft store

½” wide clear tape

Discount retail store, craft store

(Optional) black marker

Discount retail store, home improvement store

Rev:03/15/13 Project #40 Page 3/25

FPG: Sonic Silhouette

Use a sharp pair of scissors to cut the rim off of

three foam plates. Be sure not to remove any of

the flat surface of the plate. For best results, cut

about half way up on the radius between the flat

surface and the rim as shown. (fig. A)

Step 1

Apply the fuselage graphics to the second foam

plate as shown. (fig. D)

Step 4

Choose which one of the three glider colors you

would like to make from pages 20 through 25.

Print the two graphic pages required on full-

sheet printer labels. Use a sharp pair of scissors

to roughly cut out the groups of graphics as

shown in figures B through E. Cut the graphics

out with about 1/4” margin around the edges.

(fig. B)

Step 2

Apply the two wingtips and camber gauge graphics

to the first foam plate as shown. (fig. C)

Step 3

fig. A

Remove rim

from three

plates

Fig. C

Apply these

graphics to

first plate

Fig. D

Apply these

graphics to

second plate

Fig. B

Cut around

groups of

graphics

Rev:03/15/13 Project #40 Page 4/25

FPG: Sonic Silhouette

Place the foam piece on a surface suitable for

cutting. Use an X-acto knife with a new, sharp

blade for cutting the foam pieces. You can use a

metal ruler as a cutting guide on the straight

cuts. For all of the other cuts, carefully cut

freehand along the outside on the lines as

shown. (fig. F)

Step 6

Apply the center wing section and stabilizers to

the third foam plate as shown. (fig. E)

Step 5

fig. F

Carefully cut on

outside of line

Cut out all

pieces shown fig. G

Cut out all of the foam pieces shown. (fig. G)

Step 7

Fig. E

Apply these

graphics to

second plate

Rev:03/15/13 Project #40 Page 5/25

FPG: Sonic Silhouette

You can use a steel

ruler for making the

straight cuts on the

graphics. Or, you can

just go free hand like

me . . . I like to live

on the edge! Just be

careful to cut on the

lines. No wandering

allowed!

Use the tail boom graphic that you printed in a

previous step. Cut the graphic out using scissors,

or an X-acto knife with a sharp blade and a

straight edge. Remove the backing and apply to a

regular plastic drinking straw measuring 1/4” in

diameter. Careful alignment is key to a great

looking tail boom. Start by sticking down the left

corner on the center and along the axis of the

straw, then carefully align the label straight along

the axis, then stick the right corner down as

shown. (fig. K)

Step 11

Stick the fuselage halves together, lining up all the

edges flush. Lay the fuselage on a flat surface to

make sure it is straight with no warping. Allow the

glue to dry for a few minutes before proceeding.

(fig. J)

Step 10

Lay both fuselage pieces on your work surface

with the foam side up as shown. Use a glue stick

to apply a thin, even film of glue over the entire

surface of both pieces. For good adhesion, be

sure the entire surface is covered. (fig. I)

Step 9

Use an X-acto knife to cut the four tail boom

mounting slots as show. Be careful to cut exactly

on the lines. (fig. H)

Step 8

Apply a thin coat of

glue on both pieces fig. I

fig. H

Cut on the four tail

boom slot lines

Rev:03/15/13 Project #40 Page 6/25

FPG: Sonic Silhouette

Be sure fuselage is

straight with no

warping

fig. J

fig. K

Align graphic straight

along straw’s axis

Using a low-temp hot glue gun, apply a thin bead

of glue on the bottom edge of the stabilizer in

the location shown. (fig. O)

Step 15

Press the first edge of the label down on the

straw by carefully sliding your thumb back and

forth. Now, apply the label all the way around

the straw by slowly turning the straw with one

hand while sliding your thumb and fingers back

and forth all the way across the label with your

other hand. Rotate and apply until the label is

applied all the way around the straw. Be sure the

seam on the label is pressed down firmly all the

way along. (fig. L)

Step 12

Use a sharp pair of scissors to trim off the

extra straw on each side of the graphic. Use the

cut lines on each end as a guide. Carefully cut

out the stabilizer slot on the cut lines as shown.

(fig. M)

Step 13

Use a sharp pair of scissors to carefully cut out

the stabilizer graphic Peal the backing and

carefully apply the graphic to the foam side of

the stabilizer as shown. For best results, align

one corner first, then the bottom edge, then the

whole graphic. (fig. N)

Step 14

fig. O

Apply thin bead of

glue here

Rev:03/15/13 Project #40 Page 7/25

FPG: Sonic Silhouette

Rotate straw as you

slide your fingers to

apply label

fig. L

fig. M

Cutout stabilizer

slot

Trim extra straw at

each end on cut line

fig. N

Align corner

first, then

bottom edge

Apply

graphic to

stabilizer

Working quickly while the glue is still hot, insert

the stabilizer into the slot and against the inside

bottom of the straw as shown. Quickly align the

stabilizer so it is flat against the bottom, and

centered inside the straw. (fig. P)

Step 16

Apply a piece of clear tape on one side on the

stabilizer, about 1/2” up from the boom as

shown. Wrap the tape down around the boom and

onto the other side of the stabilizer. Trim the

length of the tape on the other side before

applying. (fig. Q)

Step 17

Use the Stabilizer Centerline Template to mark

a centerline on the foam side of the horizontal

stabilizer as shown. Make your mark from the

leading edge back to about where the elevator

begins. If you mark all the way across, the end

of the line will show after you attach the

stabilizer. (fig. R)

Step 18

fig. S

Carefully crease

foam for elevator

Use a steel ruler to make a crease in the

horizontal stabilizer, creating a movable

elevator. Align the ruler on the elevator line as

shown. Carefully apply pressure to the foam on

the back side of the ruler to create a crease in

the foam. Be careful not to crack the foam when

making the crease. (fig. S)

Step 19

fig. P

Insert stabilizer

flat on the bottom

and centered inside

the straw

Rev:03/15/13 Project #40 Page 8/25

FPG: Sonic Silhouette

fig. Q

Apply tape from

one side around

the bottom to the

other side

fig. R

Use template to mark

centerline here

Working quickly while the glue is still hot, attach

the horizontal stabilizer to the vertical

stabilizer as shown. Use the centerline marking

on the bottom to align the horizontal stabilizer

in the center. Be sure the stabilizers are lined

up flush at the leading edges. Also be sure the

horizontal stabilizer is aligned 900to the

vertical as shown. Hold the stabilizer in position

until the glue cools. (fig. U)

Step 21

Using a low-temp hot glue gun, apply a thin bead

of glue on the top edge of the stabilizer in the

location shown. (fig. T)

Step 20

Installing the tail boom will

take a little patience and

finesse. I designed the fit

to be tight so the joint is

secure. Just take your time

and carefully work the tail

boom into the slots about

half way like this. Installing

the boom with the tail

rotated like this makes it

easier to get it started in

the slots. We will rotate the

tail in the next step. Be

gentile; remember the

empennage is your friend!

Carefully insert the tail boom into the slots in

the fuselage with the tail rotated 900in the

orientation shown. The fit between the tail boom

and fuselage is designed to be snug, so care

must be taken during instillation to avoid

damaging the foam. (fig. V)

Step 22

fig. V

Inset tail boom

half way into

slots with tail

oriented at 900

Rev:03/15/13 Project #40 Page 9/25

FPG: Sonic Silhouette

fig. T

Apply thin bead of

glue here

fig. U

Attach on

centerline

marking

Align at

900

Taper the edges of the wing pieces about 1/2”

back as shown. It’s helpful to practice on a spare

piece of foam. (fig. Z)

Step 26

Now rotate the tail upright and carefully push it

all the way to the end of the slots as shown.

This is a snug fit and will require some care to

prevent damage as you install the tail. Check the

alignment of the tail; be sure the vertical

stabilizer is straight up and down. Carefully

rotate the tail boom to make small adjustments

as necessary. (fig. W)

Step 23

Apply a piece of clear tape on one side of the

fuselage and over the tail boom as shown. Wrap

the tape down around the bottom and onto the

other side of the fuselage. Trim the length of

the tape even with the top of the fuselage on

the other side. (fig. X)

Step 24

To improve the efficiency of the wing, use the

handle of your X-acto knife to carefully taper

the foam side of the leading and trailing edges

of all thee wing pieces. It’s helpful to place the

foam wing pieces near the edge of a raised

surface as shown. (fig. Y)

Step 25

fig. Y

Taper both

edges

Apply tape

from one side

around the

bottom to the

other side

fig. X

fig. W

Carefully

install tail

boom all the

way on with

the tail

upright

Rev:03/15/13 Project #40 Page 10/25

FPG: Sonic Silhouette

fig. Z

Taper each edge

back about 1/2”

Apply a bead of low-temp hot glue in the location

shown. (fig. DD)

Step 30

Use a metal ruler to crease the foam on the

leading edge of each wing piece. Align the ruler

with the leading edge line as shown. (fig. AA)

Step 27

Hold the wing piece vertically on a flat surface

and gently bend the leading edge over as shown.

Carefully fold the leading edge down on all three

wing pieces. (fig. BB)

Step 28

Use the camber gauge to check the camber in all

three wing pieces. Adjust the camber to match

the gauge if necessary. (fig. CC)

Step 29

Check wing camber with

camber gauge

fig. CC

fig. DD

Apply glue here

Rev:03/15/13 Project #40 Page 11/25

FPG: Sonic Silhouette

fig. AA

Crease

foam on

leading

edge line

Carefully bend the leading

edge on flat surface fig. BB

Apply a piece of clear tape to the wing in the

location shown. Trim the end of the tape so that

it extends past the wing about 3/4”. (fig. HH)

Step 34

Working quickly while the glue is still hot, attach

the center wing section to the fuselage as

shown. Be sure the wing is tight against the

fuselage and all the way forward against the

step as shown. (fig. EE)

Step 31

While the glue is still hot, check the position of

the wing looking down on it as shown. The small

alignment marks on the wing should be aligned in

the center on the fuselage as shown. (fig. FF)

Step 32

Before the glue cools, check the wing alignment

from the front. Be sure the wing is aligned 900

from the fuselage as shown. (fig. GG)

Step 33

fig. Y

fig. GG

Wing should be

aligned 900to

fuselage

fig. HH

Apply tape in

this location

fig. FF

Align wing marks

with center of

fuselage

fig. EE

Attach wing

tightly on

fuselage

Rev:03/15/13 Project #40 Page 12/25

FPG: Sonic Silhouette

While holding the leading edge joint together

tightly, apply a piece of tape in the location

shown. Be sure the joint is tight before applying

the tape. A tight fit is important because the

leading edge joint will establish the dihedral

angle in the wingtip. Trim the length of the tape

leaving about 3/4” and wrap tightly under the

wing. (fig. KK)

Step 37

Holding the tape back with your thumb, carefully

align the wingtip piece as shown. After you are

sure the two pieces are aligned with each other,

hold the wingtip piece tightly against the center

section with the wingtip elevated as shown, and

apply the tape. (fig. II)

Step 35

Now pull the wingtip down into position and wrap

the loose end of the tape tightly around the

trailing edge and under the wing as shown.

(fig. JJ)

Step 36

fig. Y

fig. JJ

Wrap tape around trailing

edge and under wing

Attaching each wingtip

piece is a bit tricky, but

I know you can do it!

Just be sure you have

the two pieces aligned

well. I like to stick the

tape on with the wingtip

elevated like this. This

will help the tape joint

to be a little tighter

when you pull the wingtip

down into position. Take

your time and you’ll get

it. If you don’t get it

right the first time, you

can carefully remove the

tape and try again.

fig. II

Attach wing to

fuselage

Rev:03/15/13 Project #40 Page 13/25

FPG: Sonic Silhouette

Apply tape to leading

edge and under wing

fig. KK

Hold joint together

tightly while applying tape

Remove the backing and apply the shock and

nose pad cutting template to a piece of black

adhesive-backed craft foam. Apply the graphic

on the back side of the foam piece as shown.

Use a sharp pair of scissors to cut out both

pieces. (fig. OO)

Step 41

The dihedral angle in each side of the wing

should match. If they don’t look even, small

adjustments can be made by carefully bending

the wingtip up or down slightly. (fig. LL)

Step 38

Apply a small bead of low-temp hot glue between

the washer location markings on one side of the

fuselage as shown. (fig. MM)

Step 39

Working quickly while the glue is still hot, attach

a #10 flat washer on the location marking. Attach

the second washer to the other side of the

fuselage as shown. (fig. NN)

Step 40

fig. Y

fig. OO

Apply graphic

and cut out

craft foam

pieces

Apply glue

between washer

location markings

fig. MM

The dihedral

angle in each

wing should

match

fig. LL

Rev:03/15/13 Project #40 Page 14/25

FPG: Sonic Silhouette

fig. NN

Attach

washers to

both sides

Remove the backing on the shock pad foam

piece. Apply the shock pad to the nose of the

fuselage as shown. (fig. PP)

Step 42

Peal the backing and apply the nose pad to one

side of the fuselage as shown. Use the location

lines as a guide. Wrap the pad around the nose;

then apply to the other side using the markings

for location. (fig. QQ)

Step 43

If you wish, you can use a permanent black marker

to color the foam on the canopy as shown. (fig. RR)

Step 44

fig. PP

Apply foam shock

pad

Use location lines to apply

pad around nose

fig. QQ

Color foam above

canopy black fig. RR

Rev:03/15/13 Project #40 Page 15/25

FPG: Sonic Silhouette

Adjusting Your Sonic Silhouette

The primary adjustment for a great

flying glider is the elevator. I will help

you find the best position for the

elevator in the next section. To

increase the elevator angle carefully

bend it up like this. If you need to

decrease the elevator angle, just

carefully bend it down in the same way.

Rigging the wings of your glider is also very important for good

flights. You should check to be sure you have the same camber

throughout the wing and matching camber between each wing. Also

check to be sure there is no twist in each wing. The best way to do

that is to look at your glider nose-on, then tilt it up just enough to

see the under side of the wings like this. Now, compare the amount

of visible wing at the tips; they should be the same. If you see

more or less surface on one side, then carefully warp the wingtip

until they match.

Rev:03/15/13 Project #40 Page 16/25

FPG: Sonic Silhouette

Equal on both

wingtips

Flying Your Sonic Silhouette

A good launch is key to a good flight.

I’ll show you how to launch your glider

first, then we’ll look at trimming the

elevator for a nice glide. Grip your

Sonic Silhouette on the fuselage like

this. Start your hand launch with your

arm back and the plane level.

Now give your glider a nice smooth toss,

keeping the wings and nose level as you

release. You don’t want to release the glider

with the wings in a bank, or the nose raised

or lowered. A nice level release is what you

want to practice. You will also want to

practice adjusting the speed of your throw.

Too slow and your glider wont have enough

airspeed to fly. Too fast and your release

will be hard to control. Just a nice moderate

speed is all you need.

Hand Launching

Rev:03/15/13 Project #40 Page 17/25

FPG: Sonic Silhouette

Ahh . . . Just right! When you have

your throwing skills perfected, and

the correct elevator setting, a

moderate toss will give you a nice

gentle glide. You should be able to

glide 10 or 20 feet - even longer if

you throw from a higher elevation.

If you have too much elevator as

shown in this example, your glider will

climb, then stall and dive to the

ground like this. If your glider stalls,

reduce the elevator angle just a bit

and try again.

Now that you know how to launch,

lets look at trimming your

elevator for gliding. This first

example shows what happens if

you have too little elevator angle.

If your glider dives like this with

moderate speed, add a little

elevator by carefully bending it up

a little bit and try again.

Rev:03/15/13 Project #40 Page 18/25

FPG: Sonic Silhouette

Once you get the hang of hand-launching your glider, try improving your

piloting skills with some cool tricks.

Glider Catch: You can really hone your piloting skills by playing catch with

another person. Start about 10’ apart, then keep moving apart as your skills

improve. Try throwing the glider a bit harder for more distance. If you throw

a little nose down and with a little extra speed, the glider will fly farther and

rise back up to the person catching it.

Try this!

Notice to Airmen: The

Sonic Silhouette glider is

best used at moderate

ambient temperatures. If

the glider is built at room

temperature then taken to

extreme hot or cold

environments, the wings

will warp slightly because

the paper label and foam

expand and contract at

different rates with

temperature changes. The

warping can be worked out

of the wings and horizontal

stabilizer with your

fingers if you wish to

remain at the new temp.

Distance: You can have a gliding contest to see who can throw the glider the

farthest. Long flights require a balance between a good throw and the right

elevator setting. Experiment with your glider. Try throwing it at different

speeds and with different elevator settings. You can get even longer flights

if you stand on an elevated place like a hill or a tree house. Push the edge of

the envelope!

Rev:03/15/13 Project #40 Page 19/25

FPG: Sonic Silhouette

Rev:12/12/11

Project #40 Page 20/25

FPG: Sonic Silhouette

Rev:03/20/13

SS9

Sonic Silhouette Graphics

Blue/Grey

(print on full sheet label)

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