skybolt_parts_026.jpgFuel tank baffle jig130 viewsThis jig was made to bend and cut out the lightening holes for the baffles and ends of the 18 gallon tank.
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skybolt_parts_018.jpgDelta center wing ribs.126 viewsThe Delta center wing section has only four ribs. The capstrip for two are 1 1/4" X 3/4" and two are 5/8" by 1/2". We made the mdf jig (behind) to trim the outer edge of the ribs so they were all the same. The less critical inside edge was cut with a band saw and sanded.
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skybolt_parts_021.jpg143 viewsRouting the outside edge of the nose ribs.
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skybolt_parts_020.jpg133 viewsRough cutting the nose ribs with a scroll saw.
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skybolt_parts_024.jpg149 viewsWe are very big on making jigs to replicate parts with precision. By making our jigs as precise as possible, all parts made from those jigs will have the same precision. We made four jigs to make the nose ribs. Rectangular plywood pieces were first rough cut with a scroll saw. Then the interior lightening hole was trimmed flush with a laminate trimmer. Next the outside was rough cut with the scroll saw and then dropped into the two jigs mounted to the plywood for the final outside trimming.
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skybolt_parts_033.jpg172 viewsA fence was put clamped to the bandsaw to make the two cuts for the notches in the nose ribs.
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skybolt_parts_035.jpgcompleted nose ribs155 viewsFrom top left clockwise- lower wings ribs, upper wing ribs, delta center wing ribs, delta center wing butt ribs, delta outer wing butt ribs. All are very precise copies. Believe me, she is obsessive about that.
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skybolt_parts_047.jpgUpper butt rib construction169 viewsTrimming back the plywood with a laminate trimmer
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skybolt_parts_046.jpgWingtip bow jig196 viewsWe like using the router with a long plexiglass base to cut a radius. We cut a second radius about 1 1/2" smaller and not completely through to attach clamps.
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skybolt_parts_066.jpgWingtip in jig180 viewsYou can never have too many clamps
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skybolt_parts_065.jpgCenter section ribs168 viewsPictured are the butt ribs for the center section before the second skin went on and the inner ribs for the center section. Also pictured is the jig to build these ribs.
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skybolt_parts_075.jpgUpper wing ribs165 viewsFrom this picture you can just make out that the nose rib and capstrip is 1/16" smaller in the area where the leading edge sits. This really wasn't that hard to do.
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skybolt_parts_074.jpgUpper wing ribs168 viewsThis is two of our completed upper wing ribs. We still need to clearcoat the outside. The hard to get to spots are already done.
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skybolt_parts_069.jpgWing tip and center section bows158 viewsThese are completed wintip bows and a completed center section bow. It is a much larger radius for the Delta upper wing.
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