14 June 2009

Spar Trimming

It's taken a lot longer than I thought to get this spar done. Having finished the laminations and ending up with a spar sized "blank", worked a reasonable compromise between the plans' dimensions and the unexplained "750 lb mod" (enabling an extra 100lbs wt to be carried on the aircraft) drawing a (slightly) curved taper from the centre to the wingtips, I had to cut it down to size. By hand. Slow but safer. After an hour's cutting with handsaw, over a couple of days I think evilly what about the power saw? It's a hand drawn circular saw. Freak me out. I draw a parallel line 1/4" outside the actual dimension to allow for blade error and try to keep the cut outside that line. I test and am able to hold it parallel. Stop the saw to assess. But before the blade slows I relax my grip, it catches and propels back along the direction of cut. Yipes! The teeth cut outside the line perilously close to the actual line. In fact right on it. I could have trashed it. Finish the job with the hand saw. Use the electric planer to smooth the rest of the cut and bring the cut right up to the line with the belt sander. Success. But will not use the circular saw again. Too dangerous. That's cut one of four on the vertical plane. Three more then rotate the spar through 90 degrees to cut two cuts on the horizontal plane.