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Larry Winger's 601XL Project
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Date: 3-7-2007
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Number of Hours: 2.25
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Manual Reference: 6W5-1
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Brief Description: Cut and lightened spar tips
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By the time the evening was over, I cut out three spar tip blanks to get two that were usable. This is because I decided to put my lightening holes in place before bending, and my first attempt at a lightening hole was a real mess. I used my new adjustable hole cutter that was so successful last night, and it really didn't work well at all. It quickly loaded up with melted aluminum in the spiral flutes of the cutter, rendering it useless until I would clean out the cutter. Then I would be able to go one or two inches, at best, before the problem recurred. I got the hole cut, but the irregularities around the edge and the heavy burrs that needed to be cleaned were significant. I remade that blank and decided to take the plunge and try the fly cutter using my variable speed cordless DeWalt hand drill. I set the torque adjustment low enough that it wouldn't catch and do damage. To my surprise, it worked beautifully. It wasn't just a fluke because I had the same experience with my 2nd spar tip blank. I marked out the top bend line and did some bend line calculations. Using a test strip I was able to achieve a 216mm web, as specified. My only remaining problem is that in comparing the drawing to the O/B end of the wing spar, I believe the spar tip needs to be wider to match with both the top and bottom spar cap angle. I need to do some more investigation before making the wrong bend. Enough for tonight.
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Two spar tips ready to bend
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