Wing's Jig

Since most of the wing's part are done, it's time to think about the jig. Looking at the plan from Sonerai, there is different versions. If we look at the wing manual, the plan seem to be for the S2 but I have the Scale 1 plan that come with the S1 plan.

To make it square and strong, with the help of Pierre, I decided to fix the jig on the hangar wall. Also, it was decided to make the frame with 1 1/2 x 1 1/2 steel angle bar. Compared to the wood that Sonerai suggest, if it take me too long before I start the wing, the steel bar will not twist like the wood could do. 

The base of the jig is fixed to the floor with high load glue. The frame is assembled with screw and bolt so, when time come to remove the jig of the hangar, it can be stowed for futur use.

 Once the frame is done, after a 24h period to let the glue dry, I made the block support. These blocks are used to support the wing. Two support have a 2in hole. These hole are used for a 1 1/2 plumb tube   that will guide the ribs during the installation on the spar.

The jig is now completed, next step is to complete the Main Spar with the Cap Strip and then rivet it and rivet the Rear Spar to the Cap Strip.

COMPLETING THE RIBS

After almost two months out of the project, I am happy to spend some time in my hangar, looking at what was done and What should I do now!!! When you start a project like this (not really complicate), when you stop for a relatively long period it's hard to remember where you stop, what was the next step and most important, did you forget anything?

So I spend some hours reading the plans again, looking the pieces done and the building log. After that time, I was able to start again. Also, I called Pierre to know if he was available to talk about the next step as I should need his help to make sure I don't do any mistake and if he could make a tool to form the lightning hole on the spar.

By the time I could get some time to press the ribs and flange the lightning hole and form the reenforcement, I did the Cap Strip of the main and rear spars.

The rear spar Cap Strip were easy to make. But, as always, time well spent help you to make it right...

1/8in hole in the rear spar's Cap Strip

Cap Strip adjusted on the Rear Spar

Cap Strip Adjusted on the Rear Spar

Finally, my schedule is ok and I can work on the ribs. So I went to Pierre's hangar and used his press to form the reenforcement and make the flanges of the lightning hole.

Using the jigs Pierre did with MDF, I put the ribs on it with a piece of rubber and pressed it. The result is awesome and make it so well.

Placing the rib on the jig.

The rib/jig is placed in the press with a rubber on top.

The result here give you a very good job.

After the rib, it's time to work on the spar. As per the plan, I have to cut a 3" diameter lightning holes in the spar and then flange it. To cut the hole, I've used a hole saw set of 3". Then for the flanges, Pierre made a useful tool, not expansive and easy to use.

Useful tool to make the flanges.

The tool installed and used with symmetrical pressure

The result.

The spar is now ready for the next step.

Now, I have to make the Cap Strip of the main spar. The 1/8" steel plates are ordered and should be delivered soon. By the time, I will start to build the jig that will be used to build the wing...