RE: Sun Ray biplane
I notched/slotted the upper wing spars, leading edges and trailing edges. My little Dremel scroll saw worked perfect for making the notches.
You can use a piece of 1/4" triangle stock to hold the 1/4" square leading edge at the correct angle for cutting the notches.
The mocked up wing panel is holding itself together without glue. I can actually pick it up without falling apart. Neat!