Chapter 14 – All CS Spar

Well, the first major build stage for both wings is complete.  For now I’ll be focusing on the Centersection (CS) Spar, with a brief intermission for working on the upper winglets.  This intermission will be brought to us while the 3 front spar wall pieces cure (2-3 days as per plans) after they are micro’d in place on the spar box.

I finished cutting the top & bottom sides (remember, front & back in the jig) of the blue PVC foam.

Chap 14 - CS spar build

I then routered out the end channels on the blue PVC foam to leave a 0.7″ wide tab for the top & a 0.4″ wide tab on the bottom.

Chap 14 - CS spar build

Chap 14 - CS spar build

I then had to micro some smaller pieces together (blue foam) to make up the full length pieces that would be assembled & make up the top & bottom walls (front & back on jig) of the spar.

Chap 14 - CS spar build

I then micro’d 3 pieces (yellow foam) together to make up the back wall (lying on the flat center shelf) & then micro’d the Left & Right outer pieces (that lie flat but slope down) that make up the entire back wall of the spar.  Again, these foam pieces cover the entire duct taped shelf.

Chap 14 - CS spar build

Chap 14 - CS spar build

I then micro’d the the 3 blue PVC top spar pieces (back jig wall) both to each other & down onto the back wall (yellow foam lying flat on the shelf).  I held the blue foam into place with nails driven at an angle into the yellow foam & strapped it to the back wall with duct tape.

Chap 14 - CS spar build

Most builders will recognize the scrap wood I used for the jig’s front wall support tabs as the same scrap that is used to protect foam shipments from Aircraft Spruce.  I screwed (not bondo’d!) these wood support tabs to the front of the jig to micro the bottom center spar piece in place (bottom spar = front jig).  I then added more front wood jig supports to micro the Left & Right side bottom spar blue foam pieces into place so that a 3-sided channel consisting of the top, back and bottom spar walls was created.  I used finish nails, duct tape & clamps to hold the bottom PVC foam spar wall in place.

Chap 14 - CS spar build

Chap 14 - CS spar build

I then micro’d on the CS spar’s yellow foam end caps–actually classified as bulkheads–with nails as well.

Chap 14 - CS spar build

Chap 14 - CS spar build

I double checked all the bonds, ensured the surfaces were all mated well together & removed all the excess micro.

Chap 14 - CS spar build

Chap 14 - CS spar build

Chap 14 - CS spar build

Chap 14 - CS spar build

With the initial stages of the spar box assembled & curing, I called it a night.

 

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