I attempted to cut one of my wing spars with the olfa knife and may have messed it up. On my initial pass, the angle aluminum I was using as a guide moved about 1mm. I ended up having two areas where it goes from 209mm to 208. From the way I read the construction standards this is past tolerance. Is it worth a call to Caleb to see if this still usable? I Had a bad feeling about attempting this with the scoring knife when I started...should a listened to my gut!

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Comment by Timothy Aanerud on February 20, 2015 at 9:39am

I cheated a bit when cutting my wing spars.  I had the metal shop shear a 12 ft strips of 0.032 for me.  And while they were at it I had them sheer strips for the rear spars too.  The strips still had jagged edges from the sheer so some filing was required to get smooth edges.

Comment by Michael Chesney on February 1, 2015 at 8:51am
I think I'm good. Being it was my initial pass with the olfa it was light. I cut out the spar at exactly 209mm and sanded out the mistakes. Measured thickness on the edges where I sanded was well within the thickness tolerance!
Comment by Bryan Ekholm on January 31, 2015 at 10:12pm

I think 1mm variance is just fine. When you put the spar cap angles on make sure that those measurements are accurate and the edge is staight.

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