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Today I made the mold for the four leading edge sections on the wings of my STOL RW 19. I first made my router patterns for cutting out various pieces of the wings. I used the leading edge pattern to make five ribs sections to make the mold out of. I added 1/2” to the leading edge and then attached the pieces to a 3/4” piece of plywood. This will ensure that the finished leading edge shells overlap the spar caps and extend into the rib bays. The part of the shells that will have all of the staple holes will then get routed off. See Photos. My leading edges will be 1/16” thick and have four 90 degree layers.
