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Builder Name:	Stan Timmerman -

Project:	Bearhawk - Patrol
Total Hours:	1029.5
Total Expense:	$10696.05
Start/Last Date:	Jul 01, 2014 - No Finish Date

Friendly URL:	https://eaabuilderslog.org?s=Patrol

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Sep 29, 2019 Master Tooling

Category: Rib Tooling

The Patrol plans come with a mylar sheet. The mylar sheet contains the airfoil shape. The sheet would not last long, so, it is glued to a piece of 032. The 032 sheet is carefully filed to the profile of the airfoil.

After the 032 airfoil master is made it is used as a template to make a MDF Form that contains all of the details of ribs.

Elevator bolts hold MDF together

Before Master rib is used as a template it is bolted together

Bottom MDF with elevator bolts, spacers , and MASTER 032, and Top Cover used to bolt together

Spray glue mylar to 032

A jig saiw is the only way to make MDF blanks.

Sep 29, 2019 Make Rib Blanks

Category: Rib Tooling

Metal Master Rib is used to make MDF forms

Metal Mater is used to make all MDF forms

Example of MDF tooling used to bend flange

Example of MDF tool for making rib blanks

Router is used to make blanks

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Upside down router mounted in table

Stack of blanks coming out of MDF forms

MDF forms for cutting out blanks

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Sep 29, 2019 Flange Tool

Category: Rib Tooling

Step 1 router a bunch of rib blanks all at once.
Step 2 debur edges.
Step 3 Press rib blank and make round flanges.
Step 4 Put blank with round flanges in a mdf assembly
Step 5 Rubber mallet $7
Step 6 Add scallops while slowly being formed

There are many ways of straightening potato chip rib once flanges are hammered.

This is my way of doing it:
Step 7 Place rib in my flange finish tool
Step 8 Press down- Clamp Flange edges with set screws.
Step 9 Use wooden dowel to force flutes into scalloped out mdf form
Step 10 Still have to over bend flange because of aluminum spring back.

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Step 1

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Step 4

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Step 10 All methods require dealing with spring back

Step 7-8-9

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This is what potato chip looks like

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Step 10

Finished no potato chip

Step 3

Step 2