Drilled 7/8" hole in Rear Spar Attach with Unibit followed by bandsaw cuts up from the 40mm base opening to the hole tangents. Used 1" spindle sander (25.4mm or 1.4mm larger than specified) to finish the top radius tangent to a point on the centerline 29mm (17mm center point + 12mm radius) up from the bottom of part. Used disc sander to form the final tangents.
Cut out 42mm x 110mm blanks for the Front Spar Attachments. Marked bend (sight) line at 21.5mm from one edge then bent over 1/4" radiused block in vice down to 101 degrees. Finished edges down to exactly 22mm using vertical and horizontal belt sanders.
Formed new set of Attachment Doublers using form blocks with 1/4" radius routed on edge. Sanded edges down to 22mm.
Note: Using the Bend Line Spreadsheet for 0.063" material, 1/4" radius, 22mm flanges at 101 degree bend yeilds a 39.22mm DL and 18.82 bend line - both of which fell a bit short on the Front Spar Attachments. Using the DL and bend line noted above resulted in one exact side and one that required removing about 1.5mm to bring it down to 22mm.
