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Old 11-09-2017, 12:52 AM   #1
mc06854
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Old 11-09-2017, 02:02 AM   #2
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Nice job.


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Old 11-09-2017, 02:16 AM   #3
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Looking good Mike, you keep working on that thing you might have to fly it? Dave
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Old 11-09-2017, 05:40 AM   #4
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Garage is a little small after Hurricane Harvey knocked my hangar down but Iím managing. Hope to get another hangar soon.Click image for larger version

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Old 11-09-2017, 05:40 AM   #5
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Looking great! Did you do your ribs by hand or? Just curious as I canít believe they arenít available anywhere. Iím having to do mine by hand currently for my lower right wing i am building. (Mine are slightly different from plans...and I decided to keep it that way since this wing matches the other three. So Iíd have to do mine by hand anyway)
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Old 11-09-2017, 05:47 AM   #6
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Yes sir, I bought the ply, routed out the ribs and sanded. All 4 of the wings ribs are done. They don’t slide onto the spars until you widen the spar holes some due to the spar plates or shimes as their called on the plans.

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Old 11-09-2017, 06:50 AM   #7
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Quote:
Originally Posted by mc06854 View Post
Garage is a little small after Hurricane Harvey knocked my hangar down but Iím managing. Hope to get another hangar soon.Attachment 29604

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Wow! Mike, I knew Portland TX was where that thing was heading, and wondered how you had fared, apparently better than your hanger! Glad your airplane is okay. Dave
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Old 11-09-2017, 01:51 PM   #8
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Thanks Dave. Luckily I had moved it a month before because it was too hot to work at the hangar. The only thing of value left there before the storm was my motorcycle trailer and a large air tank and neither one got a scratch.
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Old 11-09-2017, 02:49 PM   #9
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How did you route your ribs? Did you make one template or multiples? I have all my ribs rough cut (within about 1/16-1/8Ē from edge) but have been debating on what would be the easiest way to route them and what kind of jig I need to build to do it. I havenít routed any plywood like this before so itís been a learning experience for me.
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Old 11-10-2017, 02:55 AM   #10
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Old 11-10-2017, 02:57 AM   #11
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All the ribs use a different template, but one template will make 4 ribs. I purchased Smooth ply at the lumber yard thick enough so the router bit would have enough surface to roll on. Take your full size rib plans and using clear Mylar I traced the plan ribs onto the Mylar. Cut the rib out of the traced Mylar and transpose this onto your ply. I used hole saws on my drill press and cut out the lightening holes then used a jig saw to cut rib template. Sand to proper shape (that is the hard part)
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Old 11-10-2017, 03:24 AM   #12
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Old 11-10-2017, 10:07 PM   #13
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That sure looks sharp! Does the Starduster II call for those tubes as drag and anti drag bracing? It looks pretty simple. Do you just square up the spars and then drill the holes in the drag and anti drag tubes?
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Old 11-11-2017, 12:36 AM   #14
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I used the center section as a template to start building the upper right wing. It is swept 6 degrees so once I figured that out I was able to attach my spars to the CS by clamps and jig the spars as you see done on the work table. The compression struts are installed after the spars are in place, level and swept. Next make the strut attach points and install. Then measure and cut each straight and diagonal tube to app length. After inserting a dowel in one end of the tube I drilled the 3/16 hole, 1/2 inch from the end of the tube. Once drilled it is bolted to one attach fitting then the other end is fit and ground off if necessary and bolted like the other end..

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Old 11-11-2017, 05:43 AM   #15
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Why do I see a lot of Stardusters using plywood ribs instead of built up ribs?
Lighter and stronger. I have built both (not Stardusters) and in the long run it didn't save that much time using plywood over build up ribs. Besides it is fun to build the ribs from cap strips and 1/16 gussets.
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Old 11-11-2017, 12:27 PM   #16
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My Starduster has metal ribs.
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Old 11-11-2017, 12:41 PM   #17
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Original Starduster plans depict built up ribs. Starduster Too ribs have always been plywood unless the builder swayed from the plans.
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Old 11-11-2017, 12:42 PM   #18
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looking good Mike. if you plan on wood leading edges, now would be good time to double that nose rib at the leading edge joint.....makes it much easier/better to make that butt joint.
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Old 11-12-2017, 01:02 AM   #19
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Navybipe, what nose rib are you talking about doubling up for plywood leading edge? The center section middle rib?
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Old 11-12-2017, 12:31 PM   #20
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somewhere around half span on the wing panel...wherever your plywood pieces meet. just increases the width of that nose rib at that butt joint.
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Old 11-12-2017, 03:53 PM   #21
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Navy, I got pieces of plywood long enough to do the whole span of each wing panel. From the root rib out to where it starts to go compound anyway. Out there Iíll do the foam fiberglass thing.
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Old 11-12-2017, 04:11 PM   #22
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good deal, no problems then. my SD is still near SAT if you ever get up that way.
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Old 11-16-2017, 03:41 AM   #23
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Old 11-16-2017, 03:48 AM   #24
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Old 11-16-2017, 03:55 AM   #25
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If I buy the aluminum trailing edge from ACSS or Wicks, what's the best way to bend them to the shape of the wing trailing edge?


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