.8mm plywood for XL

[okawbow]

I want to get started on building ribs for the XL.

Can anyone tell me how much of the .8mm ply I will need for rib gussets?

Whoops! Found it! 1 sheet 4x4.

[kalazzerx]

U also need a bunch for leading-edge - may want to buy all of it at once so you do not have to pay so much on shipping.  Weight is minimal so one or 10 is about same shipping cost.

[okawbow]

Thanks Chris. I’ll be picking it up in person. I’ll go by there about once a month on average, so the less I spend at one time, the happier my wife will be.(:

[kalazzerx]

that makes sense - wish I was close enough to do the same - shipping costs can be a killer.

[Kamcoman77]

I used one, 4x4 sheet of 0.8mm ply for the rib gussets. I cut the sheet into 32, 6" x 12" pieces. I drilled a few 1/16" holes in a stack of 28 layers of 6x12 and glued round toothpicks through the stack to hold everything together. I used my bandsaw to cut stack into two, 3" x 12" stacks. I glued IronDesigns gusset patterns on each 3 x 12 stack, after adding a few extra gussets to the drawings. I then sawed all the gussets in each 3 x 12 stack at one time. I did have to sand the edges of some gussets that were a little rough. Edit: Found notes that said I had to get more 0.8mm ply to do K-block gussets. Bought 2x4 sheet, had lots left over for other things.

[kalazzerx]

I laser cut mine - had a layout similar Kamcoman77 and cut 2 2x4 into strips to match layout - about 3 inches or so - just burned a bunch from there