Cutting parts (cont)
All the templates were cut with at least a 1/4" around the perimeter: Makes it easy to cut and sand to the line.
When cutting, I left a good 1/16' around all parts and then sand down to the line. Seems like when I cut on the line, I invariably go past the line, plus I can get a smoother surface by sanding.
Formers cut save FW (1/2" thick) and F-8 (ran out of 3 ply).
Still need to mark and cut for the stringers. Will mark for 1/4" square stringers versus 1/8"X1/4" as I like the larger surface area for gluing the sheeting.
Ribs all cut: Everything to the R-7 are aircraft ply to support the gear. I've never had a gear go through the top of the wings, yet, and I've done some bad landings over the years! When I buy a kit, I have to re-cut a lot of formers and ribs as the plans call for aircraft ply on certain parts and the kit cutters don't use it, so it is usually easier just to cut my own parts. I cut inside the lines for stringers, spars, etc on the formers and ribs as the slots always seem to be a little too large: as Roy Underwood always says, it's easier to remove wood versus adding it!
Horizontal stab, elevator, vertical fin and rudder:
Had to zerox the stab saddle from the fuse plans as I think that template is missing.
Pylon parts:
Wing saddles:
I screwed up cutting these. I make the nose an extra inch longer for weight savings and forgot to add it. Have to see if I can sister the extra inch to the saddles.
Tools of the trade:
The scroll saw and oscillating sander (one that a belt can be added to) are the main tools for cutting and sanding the parts.
Initially, I was going to use the floor model band saw but the throat is small so cross cutting is difficult. A dust mask and ear muffs as I'm not as tough as I used to be! (I remember when I was a kid, safety was for wimps!).
There's really not that many parts, the bulk of the wood will be the sheeting.
Even with a shop vac attached, it makes a mess. Being in the detached shop, it's easy to blow the mess out the garage door. If it's a warm day, I suggest taking the belt sander outside and saving from making a mess in the basement or worse (a spare room).
