Wing Jigs

After a relatively long ~9 month break, back at it.  The wing kit has been invading the basement for far too long.

First step is the wing jigs - and man, these are a project on their own.

The manual calls for them to be constructed out of standard 2x4 or 2x6 lumber, but after reading the forums building the jigs out of solid commonly available timber will lead to warpage.  So my solution was to buy 3 sheets of D grade 3/4" plywood and rip into 16, 5.5" wide strips and laminate these together to make a 16' long, 1.5" wide beam.

With the beams all laminated up, the next step is to get them into a framework.  I used standard 2x6's for the lateral supports.

For the posts that support the spars, the manual calls for 4x4 posts.  I again used 3/4" ply and made some box spars - glued and nailed.

The top is just 3/4" MDF.  4x8 sheet ripped in half.

I made the framework of the table 20" wide instead of 24", which will allow a 2" clamping area around the jigs.

Once leveled, the outside table legs are bonded to the floor.  I used a heavy duty tile glue.  Then the spar mounting brackets are fabricated and mounted on the posts.  

I used a water level to align the top brackets on each side of the jig.  The garage floor has 3" of slope from end to end.  The table is quite level, but not perfect across the entire 16' span.

Spars mounted on the almost perfectly aligned jigs.  I will do final alignment prior to drilling the wing skins which is the most crucial part.

Onto the ribs!