After taking a day off I was ready to "get back on the horse." My other spars are all good and fit fine. It's disappointing to have screwed up my main spars with a stupid mistake but it's not a total loss.
My top three reasons it wasn't a total waste: .. 1) I didn't have enough material to do the false spars behind the fuel tanks, now I do. 2) After I cut up all my material for rib attach angles into 1" strips, I noticed Eric Newton cut his into 1 1/4" strips for a little more rivet clearance. I now have material for that too if I decide to do that. 3) I got to do 4 practice spars with full sized pieces when most everyone else only uses small scraps!
I cut up one of the main spar webs to use as the false spar web behind the fuel tanks. I needed to cut it right at the angle because I'm going to need almost the entire flat web piece for 7 1/2". I found it very difficult to cut but ended up doing it with hand snips after I cut too much off my first attempt with the electric snips. I router cut and deburred the spar web blank and now it's ready for the 8' brake.
Even though when using the correct rib for sizing the spar webs works very well, I decide to make a template. I played around with this for a while and made some practice bends in some scrap (I have plenty scrap now). This will give me the assurance I need next time bending the main spars. I also made a template for the false spar. I can also use these templates to check the angle on the bend when its in the brake.
