(05) Assembling Buttercup Wing -Ribs & Spars (Mike)

[planecrazzzy]

OK,
     I'm done with the Ribs.....( except the "root rib" )

Since I've started working on shaping the spar's....seems like a good time to start a "Wing" topic....

For starters....I made my first cuts on my   1" X  5"  with my table saw....

But the wood had a bow , and the cut/trimming  ....Turned out less than satisfactory...

 So,  I used a combination square , and marked a line down the lenght of the spar....

With a plane , I shaved off most of the wood....

Then used a Block sander to finish....

  First one is done and it's a tight fit the whole lenght ( 11 ft )

(Finished the second 1" X 5" spar today also)

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

PS  Sharpened the "Plane Blade" today.... WOW....What'a difference
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[rganey]

Looks good! I'm thinking of building a Buttercup and this visual info. helps a newbie like myself.


Randy

[planecrazzzy]

Hey Guys,
               Well, I've got the spars that go through the ribs shaped....Before I shape the trailing edge piece,
I'll sandwich the ribs together on the spars , and do some light sanding to get the ribs exactly the same...
Their real close already....

Once I sand where the trailing edge goes , I'll have the measurement for shaping the angles of the trailing edge spar...

                    Gotta Fly...
                                    Mike & "Jaz" in MN  ( It's starting to look like a Wing )

[rganey]

That is some nice looking wood!  

[planecrazzzy]

Actually, I'm talking with Aircraft Spruce....I knew one spar was heavier than the other...
But I didn't realize just how much....The light one is 9 lbs ,  The heavy one is 14 lbs

Thats  5 lbs different....and I don't like it...

They might send me a new piece to match the "light one",  I'm still talking with them...

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

PS  They "ARE" sending me a new Spar , to match my Light one.... No Charge.......Thanks ACS
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That is some nice looking wood!  

[planecrazzzy]

I got my "NEW" spar from ACS....Got the rib to slide down the length....
Weighed my spars together ( each wing )

Had 2 lbs difference....Switched some pieces around to get both wings to weigh the same...

Then started shaping the "ends" of the spars ( Left & Right )

Here's some pictures....

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

Today I "layed out" the spars....Trim cut them , and marked the Rib spacing....

I've got the Ribs on the Spars , I'll be ready to Drill/ screw the aileron spar on next....

I'm thinking about Stainless steel screws...

I like these "horses" .....I can adjust the leg height....

Before I do anything , I need to bring my digital protractor home and check

that the horses are level to each other....So I don't build "in" a wash.

          Had a picture with "Jaz" in it....But it came out Blurry...

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

Not bad for not having any "room".... I've got both wings ready to work on...

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

Hey Guys,
               I have the screws to attach the "aileron spar"....
But everything moves too much.....
     
       So, I stood the wing up on it's Front Spar , and glued the ribs ( w/full plywood ) to the front spar...

This morning, I went out , Turned the wings over....and glued the same ribs to the rear spar.....

 Now, the wing will hold "square" alittle better while I attach the aileron spar , and glue the rest of the ribs....

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

[planecrazzzy]

Hey Guys,
              The next step is to put the Spar "Fillers" in....

They go between the ribs....There's some questions that I've asked Earl about
Where to put them....Prints and his construction photos don't match up...

 It looks like they go on the Front Spar only ( Top & Bottom )

 Here's some recent photos....

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

PS   Earl Replied,  Yes , Front Spar only - Top & Bottom
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[planecrazzzy]

Hey Guys,
              I've got the garage closed because there's snow outside....I was block sanding the
spar filler material , power sanding just makes a mess in the garage

But that was too much work , and taking too long.... So I went at it with one of my small
air grinder/sander....wasn't too bad ....There was still alot of block sanding to do...

Later I'll just get some Fans going , and use the compressor to blow the garage out....

Now that the "fillers" are in....next is the Birch ply....followed with the triangle blocks....

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

Putting some of the Birch Plywood on the Front Spar...

The ones for the Lift Strut are 3/16 inch thick....

The ones for the leading edge pivot hinges are  1/16 inch thick

                          Gotta Fly...
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[planecrazzzy]

I put the spar caps on the "root end" today....

First , I soaked the pieces after I sanded them with a "taper"....

Then I poured a tea pot of steaming hot water on them....

Brought them out to the garage and used rubberbands to hold them in place ( twisted )

 I let them dry....

Then I took the rubberbands off.....added some epoxy , and put the rubberbands back on till

the epoxy drys.....

Tomorrow I'll put the birch plywood on the Root ends...

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

[Allen]

Mike,

I'm enjoying watching the outcome of your work.  It's excellent.  When shaping the spar ends, particularly the ones with the compound angles, did you use a saw and if so what did you use and how?

Allen in Anchorage

[planecrazzzy]

Hi Allen,
             At the Very beginning.... I tried to use a table saw for cutting....

I dropped that idea quick.....  "I"  wasn't getting good results....

 So from that point on , I've been "Planeing" and using a "Hand Saw "  (Fine tooth)

 I was able to use a couple different band saw for cutting the plywood and the small spruce.

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

I'm enjoying watching the outcome of your work.  It's excellent.  When shaping the spar ends, particularly the ones with the compound angles, did you use a saw and if so what did you use and how?

Allen in Anchorage