The rear spar has been worrying me for a while due to the length of the fold involved. Many, many swear words later it is almost done, but my bending brake is now up to about version 4. I had replaced my 2" square 3/16'' steel angle with a 4m long 100mm x 8mm plate to hold down the aluminium.......but there is a lesson here. Don't get smart and weld a 1/4" bead to one side only and not let it cool down in between each weld. I wouldn't have thought it possible, but the 4" wide strip bent by almost 2" into a banana shape! After cutting the welds, and trying to bend it back, the steel has been consigned to the scrap box and a new 10mm thick by 100mm wide plate substituted. It finally worked, but the bends require a lot of muscle and atleast one profanity! I could have made it a bit easier if I had done it in two pieces but I was determined to make it in one piece.
One banana shaped bending die.
Rear spar blank, already cut and drilled ready for bending.
