Spinal Surgery (Spar Bending)

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.


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