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KR 2s Wing Spar Construction
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Completed laminating spar caps for center and outboard wing spars. Outboard forward wing spar caps planed down to dimensions in manual drawings.
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The wing spar caps were then tapered on width and vertical dimensions using a Shopsmith with a $50 miter blade....used lots of power and generated a lot of heat and sawdust! The taper jig was constructed of a 1x6 that was run thru the saw to give where each cut would be made. The spar cap was then cleted & clamped to the jig. Had to stop to move clamps, but the cut was very smooth and required little to no sanding.
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A total of four outboard tapered wing spar caps were fabricated.
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The spars were covered with 2.5mm birch plywood on one side and trimmed with a router.
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Before the plywood can be put on second side of spar, an inspection needs to be conducted by an EAA Tech Counselor. A Tech Counselor from Chapter 478 inspected the spars on 12/12/02. Spars standing at attention and "ready for inspection"!
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The interior of the spars were coated with a diluted mixture of T-88 epoxy. Then the second plywood web was epoxied to the face of each of the spars and trimmed with a router. The total construction time was around 75 hrs. Weight of spars as follows: rear wing aft spar: 4 lb; center aft spar: 6 lb; wing forward spar: 9 lb; and center forward spar: 18 lb. Total weight = 50 lb.
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Note: Spreading T-88 on all the spar and plywood surfaces is a very tedious job and is somewhat like spreading elephant snot with a toothbrush! :o)
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