Pulled it apart again on the planet gear side and noticed the gears weren't actually on their axles. The fit was so that the planet gears were able to turn most of the time and actually transmit power til it bound up. Put the planet gears on their axles, greased everything up and worked great. Now that it's fixed it's a superior method for making long straight cuts where the edges are dead flat on both sides after the cut with no screw ups. The flat cuts with no warping is due to the fact that the shear is a 3-blade shear; two outside blades and one inside center blade, so essentially 2 cuts are
made simultaneously with an approximately 4mm wide sacrificially piece of metal that comes out all curly-Q and takes all of the warping and shear instead of either the workpiece or the stock piece.
Proceeded to cut both right wing and left wing spar webs. For the long 12' cuts I placed two
strips of leftover colonial base molding under each side of the cut to make way for the center blade. Put away remaining stock and stored left wing spar web and pieces of molding.
Scotch-brited any visible scratches and then laided web blank on work table. Squared outboard end of web and marked and flange length of 25mm. Can trim down to 20mm when done. Figured I'd make the flange first rather than try to get the flange right after having the workpiece already the correct developed length. Bent the flange in the small bending brake to 90 degrees. Marked location of 95mm lightening hole on outboard end of web. Center punched and drilled hole then setup in drillpress for cutting 95mm hole. Deburred the hole and lined everything up on the worktable. Made a 212mm angle out of .040 and screwed to table at inboard end for a reference for the tape-measure and started laying out hole pattern.
