It feels so good to be working on something other than ribs. Here’s a quick video showing how we made the 20 or so various spar plates for our Bearhawk.
These spar plates are made out of 1/8″ 2024-T3 Aluminum and will will be used to attach the spars to our fuselage (like a shoulder joint) and splice together our main spars (since the main spars are actually made up of 2 sections each).
These small pieces of metal are extremely critical, but also extremely simple to make. Best of all, they gave us an excuse to use just about every tool in the shop.
This was one of the most exciting and fun days of our project so far.
Since the spars will one day be the backbone of our wings, Caleb and I treated the bending of these spars like spinal surgery. The only problem is that neither of the surgeons have ever done this kind of surgery. Oh, well. There always has to be patient #1.
Here’s the step-by-step making of our first spar…
We took our time, made plenty of practice bends, experimented with bend radius techniques, made more practice bends, calibrated the bolts on the 8-foot brake to make the bend as straight as possible, then finally strapped in the metal for our first spar.
It’s hard to explain the incredible sense of accomplishment when you feel this proud of your work.