Project: Cozy4     -     Entry

Nov 02, 2005 8 Building the Wing Jigs Category: C19 Wing+Ail
This took a bit longer than I thought, and they aren't exactly beautiful, but I think it was worth the extra trouble. I made my jigs out of 3/4" plywood, which provides a lot of stiffness. However, the thickness makes it awkward to get the wings in, which are really at an angle to the jigs. To solve that problem, I chamfered the inside edges of the jigs so the actual contact surface of each jig is only 3/8" or so.

I also made dado cuts in each jig face a-la Dust's Tee System. By installing Tee segments made from poplar boards it becomes much easier to align the jigs when setting them up, and there's no need to Bondo them to the table.

PK note of 6/8/2020... there is a floating note in the Chad Robinson builders log:

"During a conversation on another topic, Dennis Oelmann mentioned to me that he had a wing and spar pair, completed and already match-drilled to one another. The price was reasonable and I had the money, so I jumped at the chance to save some build time here. Dennis does excellent work, often peel-plying and vacuum-bagging even very large parts. His parts are often ready to finish when they arrive.

"I still have the half-finished left wing, and the cores cut and waiting to lay up for the right wing. Occasionally in some pictures in this log you'll see them - the left wing is hanging on ropes in the hangar, and the right wing cores are on top of the wall cabinets. Hopefully one day they'll get some use."

I'm guessing that most of the early work in this section was never used, and the wings and spars are as purchased from Dennis Oelmann.

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