...three day's yield (July 24th, 00)

four aftribs and two noseribs. I think the technique is under control now. Progress is quite slow, however time is what I have more than money ;)).

This is the way I clamp the rib formers. I think this is the most convenient way, because the hammer hits go naturally ~down~. First I tried to clamp the formers in the vise, but then I have to hit horizontally which (in my view) is an unnatural way of working (notice the magnifying glass. I use it everytime when marking measurements).

In front several scratch bending results. I experimented a lot but didn't find a satisfactory way to bend the channel stock (Z04-02) reliably. The variation of the U's base was always more than 0.5mm - too much I think. I probably will bring this stuff to a sheet metal shop. For all those deciding the Sonex I recommend to buy at least the prebend metal kit.

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...cut more wingrib tamplates (July 18th)

Already got blisters at the thumb. Must have the air shears. No such thing downtown (Darmstadt/Germany) for hobbyists. The 'real' ones used at the car bodyshop are unaffordable for average people like me. So I ordered one from Northern Tools (item # 15760, 52.99$). Meanwhile I'll continue making small parts from the extruded angle stock.

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...the Art of Cutting Metal Sheets (July 15th)

As I decided to start with wingribs, I marked two nose-ribs and two aft-wing ribs and started cutting the big sheet using manual tin snips.

As you all can see the result isn't nice at all. The sheet at the cutline deforms (because one side goes down at the snips and the other wide will bend up. About 1/4" of the sheet both sides of the cutline are scratched by the snips. I also need a better physical condition when thinking that dozens more of these have to be cut this way :((

Alternatives have to be evaluated, so next I tried a pneumatic bench grinder. However this is also not optimal (isn't this guy never satisfied?). The cut is quite wide, a lot of material will be grinded off and the wheel will load up quickly. This is not the way to cut along hundreds of feet.

After trying a cutting blade and a circular saw (teeth to big) I gave up for today. On monday I'll shop around for a pneumatic metal shear - maybe THAT's IT (will be continued).

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...Hurray BIG BOX arrived (Friday July 14th 13:00)

The sheets were packed in a wooden crate, every sheet seperated by a layer of paper, all sheets wrapped in tar-impregnated paper. The packing's weight was about half of the gross weigt (about 400 lbs). Aluminum 'L' extrusions came in a separate box.

Some of the 0.025" sheets had small dents (about 1/4") probably caused by the steel strap coming thru the wooden frame. I think I can live (cut around) with this.

We were two and the truck driver for unloading. For sliding such a box from the truck better take four people!

These two carts were useless, Wheels got bent and stuck in the soil. So I opened the box and we carried sheet by sheet into the workshop.

NEVER EVER think about carrying such a sheet alone! Your neighbours would enjoy the show called 'fighting with a python snake'.

If you see this sheet the first time on the worktable ~impressive~. Then take all your will and start cutting this nice shining something.

Stamping. I'll try to place most of bends 90 deg to stamping. This is good building practice.

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...sheets (finally/hopefully) will arrive on Friday (July 14th)

today made some cut layouts. I have cut out all the shapes from Sonex'es Material Planning Guide. The arrangements of most of the ribs I don't like as in the guide. I prefer to have the bends wherever possible 90 degree to the sheet's running grain. I'll also make some parts of thicker material than the plans show.

So this is what I got (click for larger picture). The parts labelled with 'FAK' means these are included in the Sonex' 'Formed Aluminum Kit'. I was going strong to order this kit, but (air) transport costs to Germany are prohibitive and sea transport of the blank sheets took almost two month longer than expected.

According to this layout I need 7 sheets of 0.025 and 8 sheets of 0.032. What will be delivered on Friday are eight sheets of 0.025 and six sheets of 0.032. Help I need more alumn!