As I mentioned elsewhere I don't plan for this to be a step by step build log but merely add defining moments and lessons learned/tips.
So after 34 hours of filing, grinding, deburring, drilling and pouring over drawings we had the first moment where we recognised an aircraft part - the left HS - and it felt good. No major problems. The most heart stopping moment was bending HS810 and HS814 to 6 degrees after all the time spent filing, grinding and sanding them! After some schoolboy tangent calculations to make an acurate 6 degree card template, and using the technique in the Orndorff video (except I kept the peices in the vice after each small bend), the reult was spot on.
Drawing 3 calls for a minimum bend radius of 1/8" on HS810 & 814 and shows a dimension of 4 7/16" from the HS centreline to what apears to be the centre of the bend. After reading the Standard Aircraft Handbook pages 54 to 58 I concluded that the point I needed to start the bend is called the "Setback" and is K(R+T) ...... K= 0.05241(6 degrees from setback chart on page 59), R=1/8 (min bend radius defined by Vans) T=Thickness of HS810/814. This works out at just under 1/64" for each item- a pencil width! So I marked 4 7/16" from the centreline and when I inserted the HS810/814 into the vice (with wood blocks) I placed the marked line a pencil width above the block and bent the 810/814 - I DID NOT use a mallet as suggested by Vans - I used the Orndorff method - one hand supporting above the block and the other providing leverage halfway up. I bent small and often rather than in one go. Result was spot on when all clecod together- phew! Main tip is not to rush - take your time.
