I needed six different ribs. The center section (wing-fold to wing-fold) uses one size rib, but I needed 14 of them. I needed two each of the other five ribs. I decided to have templates cut on a CNC router. This was done at a nearby plastic shop called Milmar Plastics, who also helped me with the canopy. Thanks for the help Doug.	Here are the templates as they were cut by the CNC router. They are made of 1/2 inch birch plywood.
Here are the templates aligned and stacked. It's hard to tell how large these ribs are from this picture. The largest is close to seven feet long.
The next step was to cut luan to roughly the size of the templates. Since I am building a plug (male mold) and not the actual wing, I do not have to use very strong materials. I just have to be accurate. The luan is screwed to the template. The luan is then shaped on a router table. The bit has a bearing that rides on the template while the blade cuts the luan to the same size and shape.
Another view of the shaping of the ribs.	A couple of stacks of ribs waiting to become a wing.
Click on any photo to see an expanded version.

Return to Building The Wing
Return to Corsair82 Information
Return to The Corsair82 Page