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Debo Cox - Zodiac 601 XL
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Date:  9-16-2007
Number of Hours:  2.00
Manual Reference:  6W
Brief Description:  Wingtip Aluminum Sheet

Usually when I encounter a problem I'm not sure how to fix, I stop and scratch my head for a few days about it. I find that my brain likes to let things percolate for a few days before spitting out an answer. I could not for the life of me figure out how to cut the aluminum wingtip sheet to the correct size. I couldn't see the tangent lines I had previously marked on the wingtip flanges, and every time tried using my edge marker, it didn't work. My solution was to make a template out of 1/8" Plexiglass and attach it to the wingtip. This way, I could see the tangent lines and use a ruler to mark short segments to make up the curve. It worked like a charm. I was able to make up a template that not only gave me the tangent line spacing I was looking for, but allowed me to make sure that edge distances were observed, and no rivets ended up on crimp lines. Although I've put a lot of time into this wingtip, I'm very pleased with the outcome.
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1/8

1/8" Plexiglass template

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The tangent line spacing I was looking for

The tangent line spacing I was looking for

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The almost-finished aluminum wingtip

The almost-finished aluminum wingtip

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