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Its not going to be absolutely perfect. I spoke with Bob last night and he said my form was within tolerance and if you stive for 100% perfection you will never have a flying airplane.
Jig Pin Locations that are not on the plans- When I spoke with Bob he has you can use the lightening hole pilot holes for jig pins. He said you shouldn't cut out the lightening holes until the rib is formed. When you get to the point of cutting out the lightening holes, the rib will already be hugging the form. Personally, I like the idea of an extra jig pin so I can cut my lightening holes with a router, and so I can use the jig with a router to cut the blanks. On the front rib I made a hole 1.5" x 1.5" from the top tight corner.
Hole sizes- Since the pilot bit on the fly cutter is 1/4, I decided to have 1/4 holes on the lightening holes. After speaking with Bob and Desert Bearhawk, I found that its also ok to use 1/4 holes for the jig pins. So I made all my holes 1/4 ID.
Instead of trying to find steel tubing or try to order drill bushings, I went to Lowes and in the hardware section (where all the nuts and bolts are) I found steel spacers with an ID of 1/4 that were already perfect lengths. They had some that were the length of the MDF and half the size for my countersunk jig pin holes. To keep the spacers from spinning when I am drilling, I put them around a screw driver where they could spin freely and bumped them up against the disc sander to ruff them up. I then rolled them in some epoxy and stuck them in.
So far I am please with the results. I will let you guys know how it goes when I actually start cutting some metal.
Jig Pin Locations that are not on the plans- When I spoke with Bob he has you can use the lightening hole pilot holes for jig pins. He said you shouldn't cut out the lightening holes until the rib is formed. When you get to the point of cutting out the lightening holes, the rib will already be hugging the form. Personally, I like the idea of an extra jig pin so I can cut my lightening holes with a router, and so I can use the jig with a router to cut the blanks. On the front rib I made a hole 1.5" x 1.5" from the top tight corner.
Hole sizes- Since the pilot bit on the fly cutter is 1/4, I decided to have 1/4 holes on the lightening holes. After speaking with Bob and Desert Bearhawk, I found that its also ok to use 1/4 holes for the jig pins. So I made all my holes 1/4 ID.
Instead of trying to find steel tubing or try to order drill bushings, I went to Lowes and in the hardware section (where all the nuts and bolts are) I found steel spacers with an ID of 1/4 that were already perfect lengths. They had some that were the length of the MDF and half the size for my countersunk jig pin holes. To keep the spacers from spinning when I am drilling, I put them around a screw driver where they could spin freely and bumped them up against the disc sander to ruff them up. I then rolled them in some epoxy and stuck them in.
So far I am please with the results. I will let you guys know how it goes when I actually start cutting some metal.
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