Finally, time to build what most people would associate with an airplane (technically a 'vehicle' since this is an FAR Part 103 ultralight) - a wing. Only one new skill is anticipated: assembly of stainless steel cable, thimbles and Nicopress sleeves.
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| Wing assembly well under way. |
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| Use of vinyl tape to assure a closer fit between main spar and inner reinforcement tubes. In this case, two thicknesses. |
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| Place the bushing and slide the tang over the thimble and into the bushing slot... |
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| Restore the thimble to its original shape. |
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| Nicopress sleeves and press. |
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| Squaring up the frame by measuring diagonally across four long temporary bolts at the corners. Fixed in place with a wood scrap and clamps |
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| Other side (out of picture) pre-crimped, getting ready to crimp this side. |
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| Rib bending table with full-sized template as a guide |
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| The end ribs are riveted and braced. The inner six ribs will be 'floating' - secured with epoxy/fiberglass bands. |
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| Stanley saw horses were on hand and worked well enough. |
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| Finishing some ribs. Used ViseGrips, jaws partially open about 1/4", to work the ends closed. Touched up on a piece of steel rail (train track) using a bronze hammer. Clear shipping tape keeping the template usable. |
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| Ribs in place. |
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| Rib ends temporarily taped in place with vinyl tape. |
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| Another view. This was the last good weather day for the season. Shop moved back into the basement until spring. Sigh... |
