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Scratch Building XL Wing Spars

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randy(at)shadycreekoutlaw
Guest

Posted: Thu May 04, 2006 7:25 am Post subject: Scratch Building XL Wing Spars

I've looked all over the net and not been able to find a site of someone =

scratch building the wing spars...  Can someone point me to one?



Thanks,



Randy

N344RB



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dclaytx2(at)hotmail.com
Guest

Posted: Fri May 05, 2006 7:06 am Post subject: Scratch Building XL Wing Spars

I have the same problem. It seems like the wing spars just magically appear 

on all the scratch builder websites. Sure would be nice to see some photos 

of actual spar construction.



Dave



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nfivesl(at)yahoo.com
Guest

Posted: Fri May 05, 2006 7:46 am Post subject: Scratch Building XL Wing Spars

Mine magically appeared in October of 2003.  They

appeared with a weird shade of green paint.

http://www.cooknwithgas.com/10_5_03_Wingspars.JPG



Scott Laughlin

601XL / Corvair

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--- Dave and Jan Clay <dclaytx2(at)hotmail.com> wrote:



 	  Quote: 	
		   I have the same problem. It seems like the wing

 spars just magically appear 

 on all the scratch builder websites.


	


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HeatonHE(at)aol.com
Guest

Posted: Sat May 06, 2006 12:19 pm Post subject: Scratch Building XL Wing Spars

<Time: 08:25:08 AM PST US

<From: "Randy Bryant" <randy(at)shadycreekoutlaws.com>

<Subject: Scratch Building XL Wing Spars




<randy(at)shadycreekoutlaws.com>



<I've looked all over the net and not been able to find a site of someone =

<scratch building the wing spars...  Can someone point me to one?



<Thanks,



<Randy

<N344RB

_______________________

Hi Randy and List,



Since no one else has stepped up to the plate, I guess I will throw in my 

method of building wing spars.  I don't have a website so I will post a few 

pictures on the Matronics site.  Matt will post a link to the Zenith-List Photo and 

File Share when they are available.



I drilled my spar caps on a CNC Bridgeport but you can do it with a bench 

drill press if you are careful.  Match drill the spar doublers to the mating spar 

caps first. Use a drill .010/.015" smaller than your finished hole.  Clamp 

the spar cap and doubler to the blank spar web and drill through the predrilled 

holes with the proper size drill.  I used a #21 for the 5/32 rivets and a #11 

for the 3/16.  Stick a solid rivet in every third hole to maintain alignment.



I drove the rivets using a 1 ton arbor press from Harbor Freight and a 3 

pound sledge hammer.  Get the proper rivet sets from A/S and mount them on a chunk 

of steel mounted on the arbor press base to give clearance for the spar cap 

angles.  Make sure your spar is well supported and parallel to the bench when 

you are ready to drive the rivet.  Hold the ram of the press solidly against 

the rivet and give the ram a couple of smart blows with the sledge.  A little 

practice will produce a very acceptable head.  I had to drill out a couple that 

I didn't like.



Just remember to measure often and keep every thing parallel and straight.



If you have any questions feel free to ask.



Herb Heaton

601XL 50%

Turbo Subaru EA-81

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