Another productive weekend. The roof braces (PF-182, PF-183 x5, PF-184) were installed today. I had to reshape the edges of PF-182 by projecting a diagonal line onto the surface and then using the bandsaw and deburring wheel to shape. PF-183 x5 and PF-184 all have to be trimmed to length and splayed open on the ends to provide 3 attachment points (except PF-184, which gets 2). To make the tabs I measure 22.5mm in from the ends and rip the corners on the bandsaw then use the hand seamer to bend the tabs 90 degrees. When cutting thin "C" channel, use a block of sacrificial wood to place inide the channel so that the bandsaw does not grab the metal and bend it. I also used a hammer and 1/4" metal rod to lightly pound the rough edges of the tabs flat before putting on the deburring wheel. The result is smooth, flat tabs with corners having a small radius, the way it ought to be. The spacing between braces is 158mm. Next up is the cabin roof skin, which is incorrectly labeled as PF-184 in the manual, but I believe to be PF-219 since it is the only panel that fits, waiting to hear back from Bushcaddy.
