Rib Construction 
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Making the first false rib master on 1/4 plywood from Lowes. Once I get my aircraft plywood I will transfer with a router.
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Master nose piece laid over the full size plan.
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Small work area for building ribs. Harbor Freights scroll saw and belt sander.
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9" Skill band saw and fixture used to make gusset #2
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Harbor Freights ruler used as a poor mans fence. The 1/16 mahogany would get stuck under the stock fence.
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Making the first false rib master on 1/4 plywood from Lowes. Once I get my aircraft plywood I will transfer with a router.
Viewed: 1772 times.
Master nose piece laid over the full size plan.
Viewed: 1664 times.
Small work area for building ribs. Harbor Freights scroll saw and belt sander.
Viewed: 1676 times.
9" Skill band saw and fixture used to make gusset #2
Viewed: 1626 times.
Harbor Freights ruler used as a poor mans fence. The 1/16 mahogany would get stuck under the stock fence.
Viewed: 1621 times.
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Working on the rib jig. I made exact spar plugs and mounted them at 25" on center. The plan is covered with 1/16 acetate from Lowes.
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Sample test to see if Super Glue would glue 3/8 x 1/4 lexan to Acetate, worked great. Now i can finish the rib jig. Still waiting for 1/4 x 1/4 capstrips to arrive.
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Master template and the blanks cut out on the band saw.
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I drilled a couple small holes in the master and then used thumb tacks to secure the master to the blank.
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I used the band saw to get close so that the routing would be easier.
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Working on the rib jig. I made exact spar plugs and mounted them at 25" on center. The plan is covered with 1/16 acetate from Lowes.
Viewed: 1596 times.
Sample test to see if Super Glue would glue 3/8 x 1/4 lexan to Acetate, worked great. Now i can finish the rib jig. Still waiting for 1/4 x 1/4 capstrips to arrive.
Viewed: 1595 times.
Master template and the blanks cut out on the band saw.
Viewed: 1627 times.
I drilled a couple small holes in the master and then used thumb tacks to secure the master to the blank.
Viewed: 1566 times.
I used the band saw to get close so that the routing would be easier.
Viewed: 1544 times.
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P1050392
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Happy to get through these with all my fingers.
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I used a scroll saw to cut out the middle. I used some of what was removed for the tail piece.
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Very small work area.
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Form for bending cap strips.
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P1050392
Viewed: 1566 times.
Happy to get through these with all my fingers.
Viewed: 1610 times.
I used a scroll saw to cut out the middle. I used some of what was removed for the tail piece.
Viewed: 1582 times.
Very small work area.
Viewed: 1614 times.
Form for bending cap strips.
Viewed: 1585 times.
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Lead guide for my master so the router doesn't grab.
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Following the lead.
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I made all this from two, 2 x 4 birch plywood, 1/4 thick, and two 2 x 4 mahogany plywood 1/16 thick. I still need to make about 300 of gusset #3.
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Boiling cap strips for the bending jig and making banana bread. This idea didn't work so well, the bread was good.
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The first rib in the fixture with the bending jig in the background.
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Lead guide for my master so the router doesn't grab.
Viewed: 1557 times.
Following the lead.
Viewed: 1603 times.
I made all this from two, 2 x 4 birch plywood, 1/4 thick, and two 2 x 4 mahogany plywood 1/16 thick. I still need to make about 300 of gusset #3.
Viewed: 1658 times.
Boiling cap strips for the bending jig and making banana bread. This idea didn't work so well, the bread was good.
Viewed: 1546 times.
The first rib in the fixture with the bending jig in the background.
Viewed: 1606 times.
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Completed first rib. I destroyed the fixture getting the rib out. I had located some of the support blocks to close to glue joints and the epoxy stuck to the saw cuts.
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New fixture with repositioned supports and Teflon tape covering the spar blocks. They also got stuck. I later covered some of the plastic support blocks. The new fixture works well.
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New method for steaming cap strips. I got a tea kettle and clamped a section of Tygon tubing to the spout. I can fit about five strips at a time and it does a very clean job.
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12/10/2012
Today I took the last rib out of the fixture. I still have a few that need gussets fixed to the back side but I have enough to start building a wing.
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Completed first rib. I destroyed the fixture getting the rib out. I had located some of the support blocks to close to glue joints and the epoxy stuck to the saw cuts.
Viewed: 1607 times.
New fixture with repositioned supports and Teflon tape covering the spar blocks. They also got stuck. I later covered some of the plastic support blocks. The new fixture works well.
Viewed: 1669 times.
New method for steaming cap strips. I got a tea kettle and clamped a section of Tygon tubing to the spout. I can fit about five strips at a time and it does a very clean job.
Viewed: 1623 times.
12/10/2012
Today I took the last rib out of the fixture. I still have a few that need gussets fixed to the back side but I have enough to start building a wing.
Viewed: 1878 times.
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