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In Bob's book he illustrates the preferred method: He uses a brake to first bend to the maximum bend around a nose to produce the correct radius. (a nose is required for all bends since a standard brake would make sharp bends ) He then places the bent metal back into the brake and crushes it...

I advocate for a real 10 foot brake for the spars, flaps ,and the trailing edge. There is a use case for home built if you can find one of those 4 foot brakes. This one came from northern tool on sale. I thought I could use it out of the box: but it did not work I tried 3/16 drill rod -no...

I found this video helpful in getting the measurements : https://www.youtube.com/watch?v=h9fxo95D4Ik&t=5s If at all possible see if you can find a 10 foot brake (patrol needs a 10 foot brake) I used one at my local EAA chapter. EAA35 I made a variety of "shoes" out of the banding material...

I solved the metal chip problem. Some day in the future archaeologist will wonder why this one patch of earth has a high concentration of pure aluminum. They will come to the conclusion that some Indian tribe that made totem poles of iron lived there: Although the present neighbors...

My son does not believe in safety equipment, no shoes.

I could not build without a table saw. In the pictures above you can see the slide attachment I made. I can make parallel and right angle cuts in mdf and aluminum. Because of my preoccupation with parallel edges on the center rib forms (actually all of the forms) I used the table saw jig to...

For all of the locations a few very small notches were required. The rib position at the splice does require an additional cut. I like to use lathe bits as spacers.

In truth Bob told me to leave them all long and ignore the capstrips notches to start with. So all of my ribs start at parallel 31.968.(patrol) That is why I started out with them full size. To save money I cut rib blanks at arbitrary angles on a single 12 foot sheet. These means that some ribs...

I can only speak in case of the patrol. You should cut them all to the max length. In the case of the patrol the distance between the two spars is 32 inches. So in principal the ribs should be 32 -0.032/2 -0.032/2 . There is a reason to leave them long. When you cut the blanks out from a...

I copied N3uw with his "story pole " idea. I bought an extra length of capstrip material and made a template. The important thing is getting the 12 1/4 spacing correct. You can never have enough clamps. I made a transfer punch to make a dimple

In some ways it is harder to make an airplane by hand if you grew up around a machine shop. The truth is we use rubber mallets to make the wing. Sometimes I have been known to use a wood stick. For me, I control the accuracy of my measurements by using a single tape measure. I hide the tape...

If you buy the 1 inch sheet, you can make one form block instead of two. You can use both sides for forming left and right versions of the wing rib. No need for a router just round off the hard edge with a sanding block. Some times Bob says things that might mean something different that...

The question we all get stuck on is : Are you supposed to cut the master template on the inside or the outside of the line. The answer is neither . It is the middle of the line. Also I like the spray on 77 for attaching the mylar to a piece of 032. I cut to the outside of the line and...

When you move to Marshall, I think Frank (PropMan) is building a LSA somewhere around that area. Everything in Tx is 200 miles away , so close is relative. There usually is a fly in at Critterslodge (Centerville) sometime in the Spring and Fall. https://www.youtube.com/watch?v=pQP5nX_HMUU...

section aa front side

secton aa lookiing toward root

looking toward tip at rib 13 from rear side of main spar

rib 12 looking toward tip

rib 5 rear two strips

This is the most confusing capstrip direction. There are two (first layer) strips on the front side that run the length of 131 inches . Note on drawing is about the second layer. The last line in the call out wants a second layer 71 inch capstrip on the bottom of the front side. There is...