MasterClass #8, “Leading Edges,” brings viewers inside another hands-on balsa-building session with Joshua Orchard and Brian Schiller. This episode focuses on shaping the Minuette’s leading edges and wing tips—two areas critical to performance and appearance—but also covers finishing techniques, tool recommendations, and practical building philosophy.
Toledo Show, Eclipse Travel Plans & New Builds Taking Shape
The video opens with announcements about DU-BRO’s upcoming appearance at the Toledo Show & Swap Meet, along with a humorous reminder to reserve hotel rooms before eclipse tourism fills the area. Joshua shares that he plans to bring one of his newly built models to the event.
He also previews the front end of his aircraft, showing an engine-turned aluminum finish made using common ducting tape to capture that Spirit of St. Louis aesthetic. After thanking Master Airscrew for supplying props, Joshua directs viewers to his YouTube channel for a deeper dive on the finishing method.
Shaping Leading Edges: Tools, Technique & Patience
The heart of the session begins with the leading edge shaping process. Joshua starts by fitting the wing root to the fuselage using a Kwik-Sand Hand Sander, ensuring the bottom of the wing sits flush before shaping the profile.
He traces the wing root outline onto the leading edge, then reaches for a microplaner—a precise, efficient tool for removing material and establishing flat spots. When a viewer asks what to do if too much wood comes off, Joshua recommends gluing on a thin piece of balsa using aliphatic glue, emphasizing patience over rushing.
To achieve smooth, even shaping, Joshua transitions to a 22-inch sanding bar, allowing long strokes that prevent dips or uneven spots. For slower material removal and better control, he demonstrates using 220-grit sandpaper.
For builders seeking professional-grade sanding tools, DU-BRO Long Sanding Bars are a staple.
Wing-Tip Shaping & Even Pressure
Joshua then moves to the wing tip, roughing in curves using the large hand sander before blending transitions with an 80-grit smaller block. He highlights even pressure, warning that heavy hands create warps or hinge-line misalignment. These smaller shaping tools benefit greatly from precise, controlled sanding—a task made easier with DU-BRO T-Pins to secure workpieces on the bench.
Prep for Covering, Stain Tips & Safety Notes
Brian introduces a trivia question about preparing wood for stain, and the correct answer—wetting the wood to raise the grain—leads to tips on smoothing fibers before applying color.
Joshua answers questions about covering before or after attaching the stab, explaining that both methods work depending on whether you prefer integrated covering or easier epoxy access.
A brief sidebar on shop safety encourages cleanliness and dust control. Joshua vacuums often, allowing him to work in socks without stepping on debris.
Tool Tips: Microplaners, PVC Sanding Forms & Hatch Bending
Joshua demonstrates how to set the depth on a microplaner—aiming for a “deli-thin” shaving. For builders without a planer, he explains an alternative using PVC pipes wrapped with sandpaper to shape radiused edges.
Later, he revisits bending balsa for hatches, wetting the outside with Windex and gluing the inside against stringers. This mirrors earlier sheeting lessons and reinforces how moisture and patience can coax wood into complex shapes.
When preparing for hinge installation, Joshua reminds builders to use strong, reliable hinges—such as DU-BRO Nylon Pin Hinges
And for wrapping edges once covering begins, DU-BRO Canopy Scissors deliver clean curved cuts.
A Class Rooted in Skill-Building & Mentorship
The episode closes with Joshua encouraging builders to experiment, embrace mistakes, and keep learning. Whether shaping leading edges, blending wing tips, or preparing for covering, the right tools—paired with careful technique—make all the difference.
With DU-BRO tools, builder-friendly methods, and Joshua’s thoughtful teaching style, MasterClass #8 gives both beginners and veterans the confidence to shape cleaner, straighter, more aerodynamic wings.
