The plans call for forming the upper longerons with a joggle. The longeron is a 1"x1"x1/8" extrusion and the plans require a 0.075 joggle. I tried a number of methods to achieve this accurately and without out-of-plane deformation. In is notes, Dick said he did it with a heavy hammer and vice. i was not able to achieve good results with any method. So, rather than fight it, I am going to do away with the joggle. The joggle is required to accomodate the 0.040 U channel and the 0.025 flange for the baggage door on the left side (0.065 total). On the right side, only the 0.040 U channel is needed. I am going to attach the baggage flange differently so that it does not go under the U channel. Therefore, only a 0.040 offset needs to be accomodated on both sides. Rather than joggling the lingeron, I plan to use a .020 shim coming out of the U channel and then drop the shim at an appropriately hidden point. It all should be small enough to be minimally visable. In the end, I am afraid that I would do more damage to the important structural longeron by continuing with hammering in a joggle.
