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Old 09-10-2012 | 08:53 AM
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Iron Bottom
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From: Butner, NC,
Default RE: Someone mentioned warped wing

If I wanted to build something straight, wood probably be the last thing I would consider. And balsa would be the last wood on the wood list. I build as straight as possible and certainly as straight as my tools allow.

For example; a wing.
1. Epoxy two 1/8" pieces of steel that are close to 1/2" wider and longer than the rib together.
2. Straighten and square one edge of the steel patterns.
3. Scribe a line through the center of the pattern.
4. Fix printout of rib to pattern.
5. Drill 1/4" holes to fit 1/4" drill rod that will be used for a jig.
6. Rough saw the shape of the rib. One side for symmetrical ribs. Pattern will be flipped for other side.
7. Sand to finish shape.
8. Square sanded edges.
9. Saw rib blanks.
10. Lay pattern over blank and cut holes for jig. I have a paper drill, but a home made brass tube drill is a little faster.
11. With pattern on rib blank, draw rib shape on rib blank.
12. Rough cut rib blank to shape with Exacto knife.
13. Mark pattern with Sharpie on sanding edge.
14. Assemble ribs blanks onto 1/4" brass tube and slide pattern on each side.
15. Rough sand down close to pattern.
16. With finer grit, sand to final shape.
17 Turn pattern over and sand other side of ribs.
18. Check ribs by comparing outside ribs. Turn one rib top to bottom and check again. Do this on jig. Ribs are correct when no differences can be felt or seen.
19. Put ribs with brass tubes into machine vice. brass tubes on the top of the jaws.
20. Align rib notches drawn onto printout with side of jaws. Saw to correct depth.
21. Move to next line and saw to correct depth.
22. Turn rib stack over and repeat 19, 20 and 21.
23. Clear rib notches of excess material and finish sand if required.

Crazy? Probably. But I'll put my ribs up against anybodies.

I've always thought thin epoxy would be the ideal glue. I might try some finishing epoxy from Bob Smith.

Try a pop corn diet starting a week before gluing.