Just a few photos of how we tackled various construction methods. I have a very small shop and want use the most space/ time efficient ways to build the wings. Rib jig enables us to apply gussets to both side simultaneously. Clamps have nylon cutting board segments attached with bolts and o rings to allow them to float and center. The green nylon segments have wood screws just barely penetrating them to grip the plywood and keep the gussets from sliding on the glue. The construction table uses toggle "cams" to tighten spar frames against the edge guides, allowing construction of both front and rear spars simultaneously, while constructing scarf joined web in the middle. When both are complete, the middle jig then allows the two to be joined, completing the two spars, while the next two spar frames are started on the edges. Wood "clamps" are applied to the frames/ web by long screws into the table located at each 1/4 X 3/4 spacer where the ribs will attach. (A long 1 X 2 pine spacer between the spar frames and the clamps help distribute the pressure) Router set up is how we "scarfed" the 1/8 plywood to splice the 4 foot segments to make the spar web. So far the "assembly line" has been pretty quick and efficient.
