Category: Wings

I worked on drilling the second wing spar using the first as a template. This was fairly easy but time consuming. Still, it was easier than all of the layout work that went into the first spar.

Spent more time today getting the other wing spar blank made to size. I’m now ready to setup and start using the first spar as a template to drill the second spar.

I spent a fair bit of time today finishing the layout of the wing spar. Once all the layout was complete I setup my drill press and drilled the pilot holes. I still need to put in the large 1-1/2" hole but the rest of the holes are complete. My next stop will be to clamp it to the blank for the other side of the wing and use it as a template to get all of the holes drilled in that spar.

Working on layout of wing spar.

I cut out the splic plates and marked the holes.

Finished making W04-07

I started each of the four plates by cutting a length of 0.090 aluminum from the strips I had previously ripped on the band saw. Next, I filed the two long edges to get 3-3/8" inches. With this done I simply measured and marked the remaining cuts. These were then cut on the band saw. I filed and sanded the edges to get the final outside shape. Once all four were ready I started to layout the 3/32" pilot holes for the rivets. This was straight forward and I drilled most of the holes in the drill press.

These were two simple parts also. I layed these out directly from measurements onto the aluminum. Cut the pieces to size on the band saw and rounded the tip using the bench sander. Next I filed and sand the edges. I marked all of the pilot holes and setup a fence on the drill press for 1/4" as this is the edge distance for the holes. Next, I drilled all of the holes. I left the 3/16" hole for later but pilot drilled it 3/32" for now. I finished the parts using scotch brite.

I finished up the center webs today. I used a whole saw to cut out the 1-1/2" hole but I actually used a 1-1/4" hole saw then opened up the hole to 1-1/2" with a sanding drum in the drill press. I did not drill all of the pilot holes as I will wait until I create one of the other spar webs to use as a template

Today I finished the layout of the first web, cut it out and then did the same with the second one.