I have started on the bottom skin, which runs from rib5 to the wing tip. It has been marked up, but no drilling yet. Doing this by myself, I have found it very difficult to manoeuvre the 10 foot length of .025 aluminium alone! In order to make the fitting process easier, I will cut the inspection panels first. That has been a fairly time consuming task. I am using jigs and a router to cut them all identically. The support rings have been completed (twice!) It was easy enough to build a jig for these. I had more trouble creating a perfect jig for the wing skin cutout and the inspection panel itself. After 3 attempts and many wasted hours, I had to think outside the square (no pun intended). I have had a friend use his 3D printer to print up a jig for me. I used these to make MDF form blocks to create the holes and panels. MUCH easier than trying to make a precise jig by hand,
Pre-drilled holes as the part is made, in order to secure it to the jig.
Support rings complete
3D printed jigs n black, along with the subsequent MDF models.
