June 9, 2014 - Triplane: Spar Plates

I decided to construct the spar "plates".  They are eight inch wide strips of 1/8" thick plywood that run on the top and bottom of the spar ladders the length of the wing.

I started with 4' by 4' sheets of aircraft quality Finnish birch plywood bought from Wicks Aircraft Supply.
   
Cutting the sheets into eight inch strips on the table saw was a two-person job.  Lynnette and I got pretty good at it.
   
Cutting the eight inch strips.
   
An few minutes later, voila!
   
Laying out the plate segments on the spar ladders so I could mark where to scarf.
   
I developed a labeling system for each plate segment.  "L-T-1/6" would signify the Lower wing, top plate, number 1 of six, going from left to right.
   
The plate segments get scarfed for joining.  I marked each segment with pencil.  This requires meticulous attention to detail.  The left plate is scarfed on top, and the right plate is scarfed on the bottom.  Easy to make a mistake!
   
After scarfing the plates, I glued two pairs at a time on the spar table.
   
A completed pair of Plates joins the spar components on the floor.  It's a good thing I have a big basement.
   
Glueing another pair of Plates.
   

Plates complete!  Doesn't seem like that bad a deal, does it?  Think again.  Let's review the work log for what it took to build the Plates:

May 23: Cut 28 plate strips (1 hr)

May 27: Measure plates (1 hr)

June 8: Scarf Plate 1 of 6 (2 hr)

June 9: Scarf Plate 2 of 6 (2 hr)

June 10: Scarf Plate 3 of 6 (1.5 hr)

June 11: Scarf Plate 4 of 6 (2 hr)

June 12: Scarf Plate 5 of 6 (2 hr)

June 13: Scarf Plate 6 of 6 (2 hr)

June 14: Glue Plates 1 & 2 of 6 (2 hr)

June 15: Glue Plates 3 & 4 of 6 (2 hr)

June 16: Glue Plates 5 & 6 of 6 (2 hr)

That's almost 20 hours and over three weeks.

 
   
 
   
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