by Bryan Cotton » Thu Dec 31, 2015 9:38 pm
I have an idea how to make wing tip form blocks. It starts with a good profile of the wing, including front rib, aft rib, spar and tooling holes. First make a router template of all these parts as they are joined together. Next router out a bunch of 1" forms out of MDF. Glue enough blanks together to account for the flanges and the offset between the bottom skin protrusion and the top. Bandsaw a slice out of this huge block using the 45 degree angle of the wingtip. Now we have all the complex forms of the flanges captured.
I did check with the two local Sonex builders. Ken Irwin got metal tips as part of the kit. Ron Voss scratch built. He traced the shape on the skin, notched here and there, and locally bent a bunch of flanges over a piece of wood.
Bryan Cotton
Poplar Grove, IL C77
Waiex 191 N191YX
Taildragger, Aerovee, acro ailerons
dual sticks with sport trainer controls
Prebuilt spars and machined angle kit
Year 2 flying and approaching 200 hours December 23