Episode #4 of MasterClass Season 2 focuses on one of the most important structural elements of the Old School Model Works Minuette—the tail section. Josh and Brian guide viewers step-by-step through stabilizer and elevator construction, share expert building practices, and answer questions from the live chat. This session is packed with hands-on techniques, adhesive insights, and workshop tips that every balsa builder can use.
Wax Paper Wisdom: A Simple Step That Makes a Difference
Right at the start, Brian admits he forgot to use wax paper in the previous episode—a mistake that made removing glued parts from the plans difficult. Josh reminds viewers that wax paper acts as a barrier between the wood and the paper plans, preventing accidental adhesion. It's a small step that saves big headaches and reinforces the MasterClass motto: mistakes are lessons.
Tools of the Trade: What You Need on the Bench
Josh walks through the tools used during this phase of the build—metric rulers, fine-tip markers, medium CA glue, and, importantly, DU-BRO’s Kwik Sand Hand Sanders in 80-grit and 150-grit. These rigid sanding bars provide consistent, flat surfaces that are essential when leveling structural members:
T-pins are another necessity, and Josh demonstrates how to use them at opposing angles to prevent shifting during glue-up. For builders needing high-quality, durable pins, DU-BRO offers a dependable assortment:
Step-by-Step Tail Assembly
The episode follows the Minuette manual from Steps 49–59, methodically building the stabilizer and elevator:
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Step 49–51: Pinning and gluing ST5, ST2, and ST1
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Step 52–55: Creating stab tips, adding center supports, and pinning ST6 leading edges
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Step 57–59: Forming elevator tips, trailing edges, and cutting away the leading edge for the joiner
Josh explains ideal pinning angles, how to “X-pin” when wood is too dense, and how to adjust for minor part discrepancies caused by humidity or laser-cut tolerances.
Laser-cut quality is also highlighted. Parts pop out cleanly, saving time and reducing sanding requirements—something new builders deeply appreciate.
Sanding, Surface Prep & Flatness Techniques
Once pinned assemblies cure, Josh gently removes the T-pins and demonstrates light, even sanding using Quicksand bars. This ensures a flat upper surface, critical for strong glue bonds later.
For keeping assemblies flat during curing, Josh uses a masonry level, while viewers suggest granite pieces—showing how creativity and common workshop items can improve results.
Glue Breakdown: CA vs. Aliphatic vs. Epoxy
A viewer question (37:44) prompts Josh to compare adhesive types:
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Thin and Medium CA: Fast, strong, but more brittle
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Aliphatic Wood Glue: Flexible, sandable, great for larger wood surfaces
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Epoxy: Ideal for high-stress areas or composite reinforcement
For hinge installation later in the project, DU-BRO CA Hinges offer strength and easy installation:
Extra Tips: Dust Safety, Material Knowledge & Filler Tricks
Josh warns about balsa dust allergies and the importance of proper ventilation. He also measures the balsa pieces—1/16" sheeting on the outer frame and 3/32" internal structure—highlighting how the design balances weight and rigidity. And viewers share a favorite trick: mixing balsa dust with thin CA to create a strong, sandable filler.
For cutting canopies or curved plastic pieces later in the build, Josh recommends DU-BRO Canopy Scissors for clean, crack-free cuts:
A Strong Tail Section Builds a Strong Airplane
By the episode’s end, the Minuette’s tail structure is nearly complete—and far more rigid than its individual laser-cut pieces might suggest. With expert guidance, proper techniques, and reliable DU-BRO tools, builders gain the confidence and skills needed to create a durable, true-tracking tail assembly.
