RE: Making large sheets of balsa help please (Ryans Rebel)
Aloha,
I'm building a Ryans Rebel too. I'm having a Laser Cutter cut the ribs, formers, and yes the fuse sides. The laser cutter can only supply 1/8 inch ply in 24 inch lengths. My plan is to have the laser cutter cut the fuse sides in three pieces and then I'll use 10:1 scarf joints to glue the pieces together. It really doesn't take that long to feather out the edge of a piece of 1/8 inch ply .... use the plys to guide you concerning how even the edges are feathered. Then use some moo glue and 24 hours later the sides are one piece (the glue has to cure for 24 hours). Titebond works too. When done properly, the joints are actually stronger than the wood. They use the scarf joint to make spar splices in full scale airplanes .... see FAA Advisory Circular 43-13.2B for full details.
I used this method to repair a fuse on a 60 size RightFlyer for a friend a couple of years ago.
I'll try to get some pix to post as I do the job.
Ahui Ho
Safetywrench