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I guess the stars finally alligned. I took last Friday and today off from work which gave me a nice long weekend. I spent Friday hammering through the honey-do list for the weekend. This left me with three days to do as I pleased.

Well, I pleased to clean out my garage, organize, install a window where there had been plywood, and I finished forming my nose ribs.

At this point I'm actually ready to drill and cleco some stiffeners to the ribs. All I need is drills, clecos, and just about everything else that one rivets with .

Anywho. . . here's a picture of my progress for the weekend.

PK -- very impressive! Way to go.

Antony

Man, PK! Is THAT the same shop we all saw a few weeks ago!!?? Nice job! Those ribs look great! Did you cut all the lightening holes as well?

Thanks Chad. I was wondering if anyone would remember the "before" version of the shop.
here's a shot of the way the garage was:


heck, I even raked the floor this weekend.
As for the ribs, that pile represents the better part of 3 months work. They all began life as a 4x14 sheet of aluminum. I cut the lightening holes with a hole saw and flanged them by hand. I should have some video up on my build site by the end of the day if there is anyone interested in seeing the process.

I tried to put in at least some time each night/day. Most times I was successful.

Looking good PK!

Is that a CRF250X I detect in the garage? I just sold one this spring ot pay for my wing kit. Decided I was getting to old to race and couldn;t stay away if I had the bike setting there.

I have a KTM 950 Adventure for sale now if you know anyone looking. After all my fuse is supposed to be getting here anytime. Causes mixed emotions when I type that.

WOW Keith!

That is a milestone!!!

I will help ya do some of those rivets!

CJ

John, that's a CRF450R converted for woods riding. I think a 250 would cry if I got on it.

I might just take you up on that CJ.

Here's the video I made of the process:

http://www.salisburyfarm.com/bearhawk94 ... _holes.wmv

PK, my 250 cried everytime I got on it but it was still lots of fun! I finally figured out a few years ago that I had to start riding smaller stuff before I killed myself. For some reason I don't bounce very good any more.

Cool video! Looks like a lot of work making the ribs, I'm not sure I would have the patience.

WHOA!!! Looks like a GREAT WAY to slice your hand wide open if you don't effectively deburr!!!

The victory beer is a nice touch!

CJ

CJ, I took great care with the deburring, and I'm happy to report that I didn't get even one cut from doing all of that.

MORE PROGRESS:

Once again I can't believe how much I got done this weekend! I must be on a biorhythm high or something these past couple of weeks. I hope it continues. Maybe I'm just more comfortable with the process now. either way I got a lot done.

I spent a few days this week trying to figure out the proper size to cut the center ribs. I ended up creating this drawing to help me visualize the main spar and the capstrips.

http://members.cox.net/papakeith/main_spar_capstrip.pdf

Once I had it all straight in my head I got down to it. For the .025 ribs 8 center ribs get cut down 1/4 inch, 4 1/8 and 2 are full length. The 8 .032 center ribs are all 1/4 short.

Between Friday, Saturday, and today, I made the template, made the router jig, cut the blanks for all of the .025 Center ribs, and hammered the flange on half of those. Before the nights done, I intend to have all of them hammered, seemed and fluted. I might even start in on the lightening holes if I have time.

I did in one weekend what it took me better than a month to do on the nose ribs.

hmm, I need to work up an aluminum order for my spars and the .032 ribs now.

All ahead full