CHAPTER 14 - CENTER SECTION SPAR

CNC cutting the jig from particle board. The assembled jig. Let's see - aft is top, front is bottom, bottom is back, top is front.
Foam cut and half layed up. The foam edge was taped and a temporary extension strip was added to run the glass against.
Lapping the glass in the end corners was like folding a Chinese food container. All the foam attached and troughs cut - or so I thought! Are those ends sloped per the top templates? %@#$, yes! The whole spar was done inverting top for bottom, including hard points!

ENTER NOT YE FAINT OF HEART

A major screw up. This is actually the bottom, troughs cut and shaped per the top templates (I thought it was too close to the interior face). Hardpoints on the wrong face! %@#$, so . . .
The shear web in place and the bottom spar finished. The top spar and the exterior lay-ups proceeded without incident.
A template and router was used to cut and shape the spar openings. The results - a smooth, formed edge.
The front opening, glassed and router trimmed. Kent Treas contemplating building an RV after his experience assiting on the shear web and spar caps. Thanks, Kent!
The finished center section spar. What a myriad of challenges!