Bob Smith Industries 900x250 v2

Kit Plane Build-along — Florio Flyer 60 Continued

Kit Plane Build-along — Florio Flyer 60 Continued

Well we now have a total of about 3 to 4 hours into the build and the wing and tail surfaces are all finished and ready for cover. As a roundup, I changed the wing to use 2 aileron servos, and replaced the solid wingtip blocks with built up ones. The wing came out really nice and it is perfectly straight.

Even though the wing’s airfoil  is fully symetrical, it builds easily right on top of the plans.


To install the aileron servos, I doubled the wing rib in the middle of the panel, added two hardwood attachment rails notched into the bottom of the ribs, and sheeted over the ribs leaving an open bay for the servo placement. I cut holes into the ribs with a sharpened 1/2 diameter brass tube so I can snake the servo leads to the center of the wing. A string will be installed prior to covering to feed the servo lead into place later on.


Here’s the last rib in the wing panel and I glued a tip plate made from 3/16-inch balsa, cut to the shape of the tip along the center of the rib.


Two 1/8-inch wedges are now glued to either side of the tip plate roughly even with the aft edge of the leading edge sheeting on both top and botto. This helps support the center of the tip structure. Then the leading edge and the trail edge areas are filled in with balsa blocks. These are rough cut to shape and glued to both the end rib and the tip plate.



Use a razor saw and cut away most of the unwanted block material. Once you get it close to the final shape, switch to course sanding block and then use finer sandpaper to smooth it down to its final shape.


You do the same with the leading edge blocks except you do a lot more sanding and less razor saw cutting. You need to blend the shape of the wing’s leading edge into the tips rounded outline, in a semi-rounded flowing shape. So sand and check, sand and check until it looks nice and smooth.

The last part of the wing assembly is making the enlarged ailerons. I used 3/8 inch square balsa sticks and sheet stock and made the ailerons 250% wider than stock. That’s from 1 inch wide to a 2.5 inches in width!


To keep them identical, I used the old fashioned technique of building them on top of each other with some thin plastic in between to prevent them from being glued together. The outboard end is tapered in at an angle to minimize ground contact during spot landings.

Here’s the finished wing panel with the enlarged aileron resting on top. Next step is to start on the fuselage.

If you want to see my video build-along, it is on the Member’s Only Website and you’ll have to subscribe for the extra content. Go to  Click the Memberships Button to subscribe!

Stay tuned for more on this build-along.


Updated: March 14, 2012 — 5:00 PM


Add a Comment
  1. I’m so jealous you get to do this for a living. Keep up the great work.

    1. It’s a hell of job… but someone has to do it! Thanks for reading! We want to continue to give our readers and viewers of our website content you can’t find anywhere else. We will keep doing it! Thanks for your comments

  2. Wonderful information, tips and tricks. Thank you for the great reading, it’s refreshment for the soul! Good luck with the build.

  3. I didn’t think you could still get those, I had one years ago , nice flyer I still have the plans . maybe I should scratch one up LOL
    Keep us posted as to how you think it flies.

  4. Thanks for the comments Leo! I do plan to shoot some pix and video at the flyig field when this plane is done. Also I am trying to have it on display at the upcoming WRAM show in the MAN Booth. If you are interested in this and other great Florio designs, check out Dan Fedorko of Great Flyer RC. email is and phone number is 570 992 2960

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