Wing spars ?

[PSweeney]

I've seen modern CNC aluminium ones for front wings, but how were they traditionally made ? 

[dreracecar]

A process called "HAMMER FORMING"

2 pieces of thick aluminum plate in the shape of the spar less 1/16" on one and the other one 1/4" smaller.

you then sandwich the spar material (5/8" bigger than the large plate) between the 2 plates and HAMMER the edge over the larger plate. flop the plates to get your lefts and rights

[PSweeney]

thanks I thought about doing it this way but thought it may pucker on the curved edges,  think I may have more success making it out of two pieces, a flat spar clamped to a flat surface and then a 3/4in wide flat piece wrapped around the outer edge and tig'd ?

[dreracecar]

dont worrry about the nose of the spar, the curve of the skin has enough strenth to hold possision without rivets.

Ron Fourner has a basic metal fabrication book that goes through the process in detail

[janjon]

Have you any references to airfoil shapes and how to lay them out?

[George]

N & P sell the spars. We bought a "kit" and built our own wings.

[rooman]

N & P sell the spars. We bought a "kit" and built our own wings.

I use Frank and Scott's parts too as it is much quicker than beating out a set of spars and the price is more than reasonable.

Roo

[dreracecar]

But whats the fun in doing that

[JeffV8]

It saves on labor costs 

[dreracecar]

As a company or service shop I would say yes, but for an individual that wants to make somthing themselves---its something to learn.

[JeffV8]

I agree Bruce. I like to fabricate what I can..

[PSweeney]

I like to do things myself too.  I'd been thinking about how I could make a wing then saw the CNC spars and I'm sure i'd have the job done in half the time and to a better standard if I went this route but thats not how I operate.  I take pride in turning perfectly good metal into scrap and occasionally producing a part I can bolt on my digger.   It's the curse of being a perfectionist with average abilities.... It's all fun and I enjoy learning even if it is the hard way sometimes.

Question for you all.....perspex or wooden front wings...cool or not ?  seen a  few, I like to use a variation of materials etc.  I know common sense and evolution would suggest aluminium but I like the little details and want to stand out from the accepted norm.

[dreracecar]

period correct Don Long front wing kit and also used as canards without the struts

[PSweeney]

very cool thanks for posting