KitLog pro

Powered By Kitlog Pro v2.0

Terrences Web Site
' style=
Date:  3-6-2008
Number of Hours:  1.00
Manual Reference:  6W8A 4
Brief Description:  Cut plywood fuselage templates

Before drilling on the wing I made up the templates defined on 6-B-14. Actually, my neighbor, Mel Gardner, a professional carpenter cut them for me. We started with a piece of the ZAC shipping crate plywood. His procedure was as follows:

1. Select one of the original (machine cut) edges of the plywood sheet.

2. Set the rip fence on his table saw to make a cut parallel to the machine cut at a distance 485-mm from the machine cut edge, and cut the piece.

3. !st he cut the center spar template which has a vertical height of 485-mm, top of 280-mm, bottom of 203.2-mm, and an angle of 81° between the bottom and the angled side

- He used a carpenter square to verify that one end was already square.
- He made a cut perpendicular to the machine cut side at about 320-mm
- He measured the top at 280-mm and the bottom at 203-mm
- He made two marks exactly 1.5" outboard of the 280 and 203-mm marks
- He clamped a straight board precisely outboard of 1.5" offset marks
- Use the clamped board as a guide, he used his Skil saw to cut the 81° angled side
- He knew from long experience that the far side of the kerf from his Skil saw would be exactly 1.5" from the guide.

In this way he made essentially perfectly straight cuts on all sides. As shown in Fig. 1, the angle is exactly 81° as specified. All the sides were within 0.5-mm of the specification.

4. Second, he cut the firewall template which has a vertical height of 460-mm, a top of 350-mm, a bottom of 243.8-mm, and an angle of 77°.

- He cut a rectangular piece as described above with about 390-mm wide.
- He set rip fence on his table saw to cut the height down to 460-mm and made the cut
- He marked the top and bottom lengths and the 1.5" offsets
- He used the clamped guide to again make a straight cut of the angled side.
' style=

Center spar  template

Center spar template

' style=

Finished templates

Finished templates

' style=










Copyright © 2001-2024 Matronics. All Rights Reserved.