(04) Rib Jig / Buttercup ( Mike )

[planecrazzzy]

Hey Guys,
               Just posting some pictures of my Rib Jig....

I'm waiting for glue to dry.....I screwed up one hole  ( the LAST one )

I put some glue on a few toothpicks and tapped them into the hole....

"My" version of a rib jig ....has 3/16" holes drilled , w/ 3/16" Stainless Steel Pegs.....

The holes go "Through" the board ....Just incase I need to move them to remove the rib....

I put the pegs where I thought they would be needed , If I have to , I can add more...

Make a note....After cutting the "rib print" to "piece it together".....Use the "match lines" but also use the "cord line" .....it helps get it a little more accurate...

                                Gotta Fly...
                                                Mike & "Jaz" in MN ,   (Watching Glue Dry)
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[planecrazzzy]

      WARNING :

I'm posting a picture that shows a flaw in the Quality of the print...

If you look down the bottom "Cap Strip" you see how the line is wavy....

This screwed "my" ribs up.... I didn't notice it until I was done....

I hit the "waves" just WRONG in that area , and I have a flat spot on all my ribs...

 (  3 of those pegs are "inline" )

          Check yours , I don't think Earl's changing it...

                       Gotta Fly...
                                       Mike & "Jaz" ( With "NEW"  Airfoil )
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[planecrazzzy]

Putting some spruce in the Jig

[planecrazzzy]

Update on Progress....

I "primed" my West System "measuring pumps"

and I gave a Squirt of Resin & Hardener in a plastic container....

It was too much for my glue job....( I'll have to watch that )

After I glued everything , I brought it into the house.....

70 degrees is a better curing temperture

There's no smell to the stuff...

I had put pieces of wax paper around all the glue joints....

I'm gonna put a full sheet of wax paper on the next one , I'll cut out where the pegs are...

                                    Gotta Fly...
                                                    Mike & "Jaz" in MN
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[planecrazzzy]

Got a few more Pictures...

The wax paper is working GREAT....

I didn't put a full sheet on the jig , But I have better coverage than using

all those little pieces...

I tried a few different ways to git the Wax Paper over the pins...

what worked was marking them with a "sharpie" , then melting holes w/ soldering Iron...

It made a good fit...

                                    Gotta Fly...
                                                    Mike & "Jaz"  Watching Epoxy Dry
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[planecrazzzy]

Here's an update.... Need 14 of these 3/4 Ribs....Half way there...
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                      Gotta Fly...

[planecrazzzy]

Hey Guys,
               Moving along, the 14 ribs ( 3/4 ) are all out of the Jig....Time to make some Full Size Ribs...

I added the Blueprint ( Leading Edge )  to the Jig....and Drill and added Stainless Pegs...

The bend is a little too much....So I wet the wood , and clamped it in a position to dry....

Hoping this will pre bend the cap strips enough for a good fit....

Oh,  I sorted through the wood a little , to find some pieces that bend easier....( some are pretty Stiff )

Here's some pictures...
                                 Gotta Fly...
                                                 Mike & "Jaz" in MN
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[planecrazzzy]

Pre-bending  the Ribs that way,  Wasn't good enough.....

I ended up soaking the ends in Hot water for about 20 minutes....Then put them in the Jig....

That seemed to work....

Picture time...

                                            Gotta Fly...
                                                             Mike & "Jaz" in MN
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[Sean_Caranna]

Good looking ribs.  What kind of epoxy are you using?  T88?

[planecrazzzy]

Hi Sean,
            It took longer than I planned to get started on my next plane....

But it's moving along now.... ( Cash & Time )

The Epoxy is West Systems.....I think Resin 105 ,  Then I got the Fast cure hardener 205 (?)

It sez fast cure.....But their talking around 9 hours....

   Got the Garage heating up right now.....Ready to jig up another "full rib"  ( only 4 of them total )

Have you read the "Steve Wittman" story that I posted in this Wittman section....You should....good story...good guy !
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                   Keep it simple,
                                         Gotta Fly...
                                                         Mike & "Jaz" in MN  ( Getting Colder )

Good looking ribs.  What kind of epoxy are you using?  T88?

       

[planecrazzzy]

Here's some more pictures of the latest progress....

First picture has the ribs "layed out" on the plywood....That way , 4 pieces can be cut out of 1 sheet.....

Second picture is preping the ribs ( sanding ) to glue the plywood...

Third picture shows the plywood ( cut a little big ) before gluing...

[planecrazzzy]

I got a little further with the Full ribs....

I've got the Mohogany epoxied on the one side.....I used alot of weights and it
laminated real good....

Before I put the ply on the other side....I drilled some holes where the spar goes...
That'll help me when I start to cut out the plywood in that area....

Then I trimmed up the plywood on the rib , so I'll be able to see where to trim the
other side.... Trimming both sides at the same time would be hard to do....

When I put the plywood on the other side , I'll coat "everything" inside the rib with
the epoxy....I have a bunch of disposable acid brushes....

Here's some pictures...
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                       Gotta Fly...
                                        Mike & "Jaz" in MN

[Sean_Caranna]

Makein' ribs!  You sir are a BBQ master

[planecrazzzy]

   Hey Sean,
        I'm just trying to Show the various steps during each of the building stages.... Kind of like my Kolb build/improvements....
Hopefully I'll be done with the Rib stage soon , and move on to the Wing stage....
Glad your there to "bump" the "allowed size"   for posting pictures....
I'm a slow typer , and a picture is worth a THOUSAND words....

As for BBQ ribs.....I do OK , nothin that would win an award.....( they only eat'em cause their free )
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                                      Gotta Fly...
                                                       Mike & "Jaz" in Brrrrrr MN
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Makein' ribs!  You sir are a BBQ master

[planecrazzzy]

I was told a little trick to clean up the plywood around my Full Ribs.... It's a Router bit with a roller bearing...
and it cuts "flush"...

Wow , it's fast , and does a great job.... Although , I clean the corners with an Exacto blade....

                                                      Gotta Fly...
                                                                      Mike & "Jaz" in MN