Mike Couts after the first high flight! Sept 30, 2001

Our story follows:

July 5,2002. Getting very serious about finishing the glider but mat keeps tearing things apart and Mike just can't keep up with the rebuild!

	the rudder addition once covered with a glass sheet will help seal the large gap.
	Keith Ashford helping cut the foam on the rudder.
	New arrangement of return springs on the spoilers.
	A new aileron bearing replacing the old bushing. This is temporarily held in place with two pop rivets.

June 30, 2002. A lot has happened....we put the wings on and soon figured that the spar fittings needed re-reaming and reinforcement. Headaches... you bet! Poor workmanship really causes problems for future rebuilding such as we are doing. While this is critical of the previous builder, and does seem harsh, all persons thinking of buying a used glider must inspect the workmanship carefully.

	The new design of the spliler pulley bracke. The pulley is actually free floating and held in place with the assistance of rubber washers to preent abrasion of the fabric while in transit. We have removed the previous bracket and replaced the spoiler cable with 3/32" cable rather than the 1/8"
	Thee method of comparing wing incidence. And yes the right wing had a greater angle of attack!
	The reamer mounted on a air driven ratchet, lubricated with kerosene.
	We had a problem! There jsut wasn't enough of the fitting touching the taper pins so we decided to weld on an addition( seen resting o nthe top of the wing)
	Mike tack welding the metal additions to the main fitting so we could get the correct placement for welding.
	The tack welded additions to the spar fittings.
	The new ball bearing aieron belcrack temporarily pop riveted on.

June 26, 2002. The both Ailerons are finished so on to getting those ailerons correct. One of the things we did not like was the lack of room for the spoiler springs on the upper surface sooo.... we made some changes and actually drilled a 3/4" hole in the shar web for our "spring extender".

	picture of spring extender that goes inteh spar. The lip on tghe left is for the lower surface spring!
	The hole in the shaer web.

June 23, 2002... busy at it!!! But we are finished the ailerons!

	The last hot wire cut on the ailerons!!!
	Mat sanding the aileron ready for the fiberglass and shrink wrap!
	The last aileron covered and curing in place.
	weight of the left aileron is 2 lbs 14 oz

June 12, 2002. The right Aileron is roughed out ready for hot wiring!

	Mike snapped this picture... really made us feel like these wings were making progress!
	Mat taping down the aileron blank to the aileron spar.
	The aileron ready for hot wiring!
	Mike cutting the aileron blank with his newly invented hot wire router!

June 10, 2002. That 6 minute aileron works!.... except for the stupid mistake that mat used two layers of10 oz instead of two layers of 6 oz

	Mike checking out the curing of the aileron.... note we cured it in place on the wing! The trailing edge is very straight!
	Mat and Mike hard at work laying the glass!
	Doing some heat shrinking before attaching the aileron to the wing.

June 5, 2002. Yes we have been making progress!The aileron has a hard point, and we are ready to epoxy on the top surface of the aileron.

	The next aileron layup for the aileron June 4, 2002
	Mike carfully laying in the cloth

May 23, 2002. Lots has happened! Mike and I decided that we would make 6 minute ailerons.... well thats what I call them after my 6 day wings that took about 2 years to finish on another project!After junking the old ailerons we needed new ones... so here is our effort!

	Well we removed the foam aileron, sanded it slightly, glassed the one side and then applied shrink wrap to give a very smooth surface..... now to glass the top side!

	We made a fiberglass spar
	Mike invented the hotwire router to get a perfectly flat edge to epoxy to the spar.
	The foam is then epoxied on the spar.
	Mike then invented the small bow hot machine to cut the trailing edge and lower surface of the aileron.

May 7, 2002. Well after those fantastic flights in the Monarch we are back on the Pioneer. The airfoils are nearly done.... next on the list is new ailerons!

	The final wing panel being glued down!

May 2, 2002. Good progress! Jim put the new wingtip on the left wing of the Pioneer and Mike and crew epoxied on the right root wing panel!

	The left wingtip epoxied on. Note the pioneer III fuselage in the background.
	Mike Couts setting in the go bars to glue down the wing panel

Past history of the Pioneer rebuild

RETURN TO: MARSKE FLYINGS WINGS HOMEPAGE

Designer:
Jim Marske

Phone :(740)-223-3550
Marske Flying Wings
c/o Marion Industrial Center
3007 Harding Higway East
Marion ,OH, 43302