Paul

  For those willing to build with epoxy, I think, the best would be to
  purchase directly made sheets to be glued on rib

  Not the cheapest way, but by far the quickest giving a superb
  result.

https://www.rockwestcomposites.com/plates-panels-angles/carbon-fiber-plate/carbon-fiber-fabric-plate/plate-carbon-fiber-qiso-tri-axial-gloss-matte-48-x-120-x-0-050-inch-thick-options



  pascal Virlouvet


  Thanks Pascal

  I have the wing rib problem decided. This is a teflon mold .75 inches
  thick. The procedure is wet out the fabric and place it over the
  center piece hole. Press the rib form into the center mold. the
  flanges will be automatically formed. Put it in an oven set to 200 F.
  Let cure.

  Teflon is good to 500 F.

  Each rib will be precisely the right size. Cut a hole for the spar
  and use  sort pieces of carbon fiber angle to bond and pop rivet the
  rib to the side of the spar.

  This will be much faster then making each ribs out of foam and
  covering it by hand  with fabric glass or carbon.

  Patent applied for :-)

  Paul Lamar

Pardon the "Captain Obvious" visit... The same process works very well for bulkheads and fire walls. Screw the hole plug to the base also for accurate hole location of wire/control looms. A piece of fiberglass tubing inserted would give a nice clean finished hole.

Michael Nash


Paul

I am building a BD4C

I use aluminum sandwich panel, skins is 2024T3 and core is honey structure aluminum 5052.

Make holes in it to lightening those ribs.
To be machined with a router for wood.
Just need a laser cut to size iron 3 mm thick rib to serve as a guide for the router.

If you want photos let me know.
But it is really stiff light and easy to glue or with epoxy of polysulfide rubber (for flex)
You even can fabricate flange to englarge contact with the rib.
Here a link for the right ref to use and the supplier in USA


http://www.generalveneer.com/bulletins/PB331.pdf

Copy paste the link, sorry my computer refuses to insert web inks....

Best regards
Pascal

BD4 is a great design. Easy to build. Jim Bede has a great big lathe and
is now turning down the wing spar between the rib. Cuts a lot of unnecessary
weight.

I am always interested in photos.

How thick are those rubs?

BTW the lower motor mount tubes need to be one inch in diameter. 3/4 is shown.

Paul Lamar


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