A little progress XL H-58

[Chuck in Indiana]

While waiting for John to send me the materials kit, I've started getting ready.
Built some pretty accurate saw horses, and a 32"X14' bench.It's flat and level.

Made a rib jig..

the cams were cut from an antique wooden curtain rod, and appear to work very well. The cap strip is some I've had laying around for years. I'll use it as masters to make the real ones.
The next project will be figuring out how to make the gussets and a way to clamp them down, if possible. Is there a list somewhere that lists how many of each are needed?
Gave the cams a coat of varnish, and called it a day.

[Kamcoman77]

I'll try and find the number for each gusset, but I'm not sure if I have it written down. One tip, cut the bottom wood strip on your rib jig to leave a gap where each vertical or diagonal meets the bottom capstrip. My rib jig was like yours until my first rib. I got too much glue oozing out of the joints and glued my capstrip to my jig base. It appears you are using the Iron Design rib plan from the shape of the gusset outlines. Is that correct? The clothespins in the photo were used so I could glue a complete rib with all gussets in one sitting.

[Chuck in Indiana]

I'll try and find the number for each gusset, but I'm not sure if I have it written down. One tip, cut the bottom wood strip on your rib jig to leave a gap where each vertical or diagonal meets the bottom capstrip. My rib jig was like yours until my first rib. I got too much glue oozing out of the joints and glued my capstrip to my jig base. It appears you are using the Iron Design rib plan from the shape of the gusset outlines. Is that correct? The clothespins in the photo were used so I could glue a complete rib with all gussets in one sitting.

Thanks for that. I've never had a problem with glue sticking to the jig after varnishing it and giving it a good coat of paste wax, though.

[Dan_]

Here is a video I enjoyed very much from Les Homan.

[Chuck in Indiana]

Thanks for that. Pretty much what I was thinking of. Ordered a handful of 3/16 carriage bolts and flanged wingnuts from McMaster Carr Aircraft supply. I have a sheet of 5/16" delrin (I have *lots*  of delrin) to use as pressure plates. No worries about glue sticking to that..

[Chuck in Indiana]

Took a break and did some social distancing. 

[Chuck in Indiana]

Router template and a "for instance" part made out of some aircraft plywood that has been laying around for well over 20 years.    Time flies..

[azevedoflyer]

Chuck,
Here is my "Social Distancing" machine.
A relative of yours but not so nice looking!
However, she is good on bones and heart (O320 A2B - 150 hp)and dearly loved by all in the family. Me specially...
Building a DE. 20 ribs done. Changed wing section to GA30A418 (H. Riblett)and will stretch fuse by 3 feet to compensate for nose heaviness as reported by some.
Cheers,
Miguel Azevedo (NW GA)

[Chuck in Indiana]

In the spirit of "doing something every day.." I've finished all the router templates, and today finished the scarfing jig. I made it of stuff I had laying around, of course.

Cut some scrap 1/8" aircraft plywood.

Close enough. I'm about out of things to do until material gets here.

[Chuck in Indiana]

Yay.. one airplane.
Some assembly required.

[Chuck in Indiana]

Now, I can finally get started.

but first.. yesterday was Mouser's 38th (!!) birthday, so we had to do a birthday flight.

As I was taxiing to the other end of the runway, I noticed my mouth getting dry.. and thought, "what's up with this?" Then, realized it was a Pavlovian response. Back in the day, on the first flight of the season Mouser used to say, "Are you bringing your A game, boy?"  Now, after all those years, she's as familiar as an old shoe.
I've read the Legal Eagle is a *good* flying airplane.. but it has big shoes to fill. 
Made a sacrificial fence for the new saw to cut the quarter inch square stuff.

Ran out and bought a new paper cutter.

The adjustable parallel and angle plate make easy work of accurate cuts. The plan is to make "some" of all the gussets. Did that yesterday. Today, I'll cut all the quarter square pieces, and hopefully tomorrow start building ribs.

[Chuck in Indiana]

Well, that didn't take long..


Now, there is a sincere and monumental amount of sanding to do. I bought an oscillating tool. Is there a better way?

[jrbirdman47]

If there's a better way to sand, I never figured it out. I liked the ocillating sander a lot. Just had to be careful not to over-do it with that thing! Also, no matter how much you don't feel like it, you'll thank yourself later if you sand the finished ribs and various wing components BEFORE assembling the wing. It is so much harder to do once put together.

[Chuck in Indiana]

Thanks for that. Oh, yeah.. I was just looking at the sticks and trying to figure out a better way to sand them before assembly. Also, birch ply "needs" to be sanded for glue adhesion is stuck into my failing memory. Mahogany, not so much. I'll sand the *next* batch of plywood before cutting them out. 

[Chuck in Indiana]

First rib in the jig. Tomorrow morning, I'll see if I glued it to the jig. 
I put two coats of spar varnish and two coats of paste wax on it.