I used to make the Swee' Pea wings from 3/32" balsa. I used 1.4 ounce cloth on the outside and 0.7 ounce on the inside. The problem was that the trailing edge is hard to do with the thick skins and the complex curves of the tips don't always lay down unless you use soft contest balsa. So I decided to switch to 1/16" skins. I'm using 1.4 ounce cloth inside and outside.

This change requires a whole new set of templates for the internal structure. The internal structure consists of the spar, ribs, blocks for the front wing hold down bolts, and pieces in front and behind the hinge line.

I've got to cut some cores and sheet a couple of wings today, but making the structure and closing this wing is my priority for the next two days. Since I don't have any CAD drawings of the wing, I have to use mechanical methods to make the templates for the structure. As I will be creating documentation, it only takes a little extra time to post here, so I'm going to post pictures and words. That way you and my customer can see how I do the work.