Made a test bend this morning to confirm my calculations for bending the center spar front web. It worked great, so I bent the front web on the brake. After that, I cut the 1/4" aluminum bar spar caps on the table saw, which worked really well. I bought a nice finishing blade that has a really high tooth count, so the cuts almost need no dressing - they're VERY clean. Measured and fabricated the reinforcement angles. I still need to pilot drill those, cut and flange the lightening holes in the spar webs, and make the spacers that go between the webs. I had originally dreaded making the spacers until I saw how cleanly the saw blade cuts. I should be able to mark the proper length and saw them right off with super-clean results. I've been reading up on drilling close-tolerance holes for bolts so that's the next major step. Since this project started, I've been intimidated by fabricating my own spars, but like everything else, with a healthy dose of precision and common sense, it's turning out to be no problem. I hope I don't eat those words!
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