I created a nose rib template out of some leftover flooring laminate stock. I use this with a vaneer trim bit in the router to create the noseribs with a fair level of duplicity. After cutting out a few nose ribs from 1/4" birch ply, I glued one in place on the root rib. I also glued up the root rib for the starboard wing. Pictured at left is the full complement of ribs for the port wing.

2 hr




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Glued the port side root rib to the scarfed plywood.

1/2 Hour

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I spent some time today working on making nice scarf joints. The ply that I had ordered wasn't long enough to cover a rib in one piece. I had my best results using the router jig shown in the first pic at the left. It is simply two steel rails attached to a board, spaced about 3.75 inches apart. One rail is shimmed up 0.25 inches to establish the 15:1 taper. Simply slide the plywood under the higher rail, then glide the router over it. I sacrificed a cedar shingle to hold the thin plywood flat. You can see the results in the second picture.

The last two images demonstrate what happens when you aren't careful using the sanding technique. I sanded one taper too long, and so even though one side looks pretty OK, the other side has exposed the laminating resin of the plywood. Scrap.

2 hr






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Glued up the root rib for the port side wing. As this rib will have birch ply covering one side, I left the bottom gussets out.

1 hr

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That's the last of the ribs requiring aileron hardpoints.

1 hr

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1 hr

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1 hr

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1 hr

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I didn't like the process of gluing on the extra gussets and hardpoint after removing the rib from the jig, so I removed the forming blocks in that panel from the jig, allowing me to assemble the whole rib with hardpoint in one shot.

1 hr

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Cut out the aileron hinge hardpoint from 1/4" birch ply and glued it in place along with the remaining gussets for this rib.

1 hr




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