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  #21  
Old 11-07-2020, 07:33 AM
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The next stage was to create two full blanks for the upper and lower wing sections and two half blanks to create a central section - as a stiffener and reinforcing section for the proposed mounting pole:

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  #22  
Old 11-07-2020, 07:42 AM
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Work on the upper wing section was a little tricky as it was a five feet long panel and Iím alone in the shop. I started with a very low crown lower anvil and worked the panel shape judiciously - very slowly - and alternated strokes past the centre line and some to the centre line. I then swapped sides and worked the other end of the panel using the same technique of stopping on stroke at the centre and the next past the centre. The reason for doing this is that if I stopped all the strokes at the centre, the panel would have a ridge in the middle and it would be very difficult to smooth out the deformation.

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  #23  
Old 11-07-2020, 07:46 AM
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Here are a couple of shots of the upper wing section:



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  #24  
Old 11-07-2020, 07:56 AM
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To create the forward return edge of the wing I used a urethane upper hammer in my Pullmax over the desired radius anvil. The urethane hammer has two benefits: one; itís non-marring and two, it can be used for shrinking edges very successfully.

Hereís a YouTube clip of the action. Notice a plank of wood clamped to the wing at either end. This is to ďtrapĒ the shape over the width of the wing whilst the forward edge is rolled over. Had I not trapped the shape widthways, the wing would have curved over widthways with the turning over of the leading edge. I hope you can make sense of my explanation as itís possibly not all that clear.

https://youtu.be/gVXxiMtAef8
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  #25  
Old 11-07-2020, 08:08 AM
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The lower wing section was created on the English wheel, similarly to the upper wing skin. However, it is much flatter from fore to aft, and does not have a leading edge return. The wing rocker in this shot looks acute - this shape pings back when the two wing halves are united.

Also note the central wing reinforcement panel - this holds an aluminium pipe to support the stand mount. It looks really spindly - but the tube gets reinforced later on in the project with a composite of 12mm 8.8 grade thread bar, 1 1/4Ē stainless steel tube and 3/4ď chrome moly tubing, all bonded together with special resin.

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  #26  
Old 11-07-2020, 08:11 AM
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In this Shot Iím lining up the sections and checking fit, and making necessary adjustments.

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  #27  
Old 11-07-2020, 08:14 AM
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The wing sections and the fuselage laid out together. Things are moving on nicely!

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  #28  
Old 11-07-2020, 08:23 AM
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Joining the upper wing section to the fuselage required literally hours of careful cutting and filing of the wing to allow the fuselage to sit in the wing. I wanted the weld to be invisible and as strong as possible. Hence choosing an almost monocoque construction of welding the inside of the wing to the fuselage lower section, then adding the central reinforcement structure and welding that to the centre of the fuselage. This created two separate wing mounting points and a much stronger structure.



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  #29  
Old 11-07-2020, 08:28 AM
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The lower wing section is then welded to the upper and inner wing structure, and a V-piece is fabricated and welded in to create the two radii on the lower wing structure, albeit with artistic license to give a sense of motion in flight...

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  #30  
Old 11-07-2020, 08:32 AM
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Hereís a YouTube clip of the wing being welded to the fuselage:

https://youtu.be/J86lTuKcsr0
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