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Debo Cox - Zodiac 601 XL
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Date:  5-14-2008
Number of Hours:  1.50
Manual Reference:  6B
Brief Description:  Left Lower Longeron

I bent the left longeron today using my bending jig. This is a version of Larry MacFarland's way of doing it. He used more clamps and actual rollers. I used the waste plugs from my hole saw. I bolted them firmly to the table using 3/8" bolts 11" apart, then cut one of the plugs in half to give the c-clamp a rounded edge to bend with. Just do little bits at a time, then check it against the bottom skin. Make correction bends with your hands across the corner of the table as needed to end up with a nice, smooth curve. This is one of those thiongs I was sweating that turned out to be really simple. Next I made a joggle tool as outlined in the photo guide and experimented on the first of the z-angles. I'll do a bit of tweaking for a better fit, but it got really close just whacking away.
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Left longeron bent to match bottom skin

Left longeron bent to match bottom skin

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My bending jig

My bending jig

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Joggle detail

Joggle detail

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