Well tonite i made the leading edge form to be able to cut out the leading edge ply gussets. I had to remove the acrylic sheet from the jig to get the proper shape of the leading edge. It was easy to just remove the screws,slide the acrylic back, draw the outline of the airfoil on a sheet of paper layed over the jig and then screw the jig back down. I then cut out the shape on the paper and overlayed it on a piece of MDF. Redrew it onto the MDF and made a rough cut. After getting the basic shape, the hard work began. I started to sand the MDF on the disc sander getting as close to the line as possible but not over sanding. Once i got close to the shape i needed i would sand alittle, place on jig to check fit, then sand some more. Check on the jig, then sand some more. I did this about 100 times. They say "Patience is a virtue". If i wasn't having so much fun i would have gone insane. I almost had a perfect fit but had to quite for the night. I'll finish it tomorrow.
