Cutting out and gluing together the internal structure from foamboard:

Motors attached to 3D printed motor mount and hot glued to the structure. ESCs attached with double sided tape:

Connecting the servo linkage for the control surfaces:

Installing receiver and Teensy 4.0-based flight controller:

Internals wrapped in cylindrical foam and landing legs glued on:

Parts all designed in Solidworks 2020 and masses used to estimate vehicle center of gravity:

Print all the parts in PLA or ABS (quantities of each part listed in part name):

Install motor mounts to motor bulkhead with m3 hardware:

Install 4 SG-90 servos to servo bulkhead with hot glue and servo hardware:

Install electronics on electronics bulkhead with double sided tape:

Install servos in the nosecose and assemble canard hinge:

Slide all subassemblies over carbon spars of ~400mm length. Servo bulkhead placement is dictated by rear flap hinge. Pin all parts in place with hot glue. Cut out aerodynamic surfaces from foamboard and slide into hinge pieces:

Cut out foamboard to snugly wrap around outside and pin in place with tape so that it can be taken off later to access electronics:

Give it some paint: