# Replica plans SE5a

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#### wiloows5050

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With three builders logs here I’ve been trying to decide if it’s worth start this one here. With all the craziness going on i needed something that was simple to work on. I have the SE5a plans from replicraft but they are way to complicated for an average build. These appear to be a quick build. With (1) Jurca, (2) Sindlinger, (2) Graham Lee, (1) Aerodrome, (1) Sands, (1) Replicraft projects and a Dh82a tiger moth restoration currently going on, I only started this as a sanity check.

#### wiloows5050

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At week at home seems to help move things along. Still a long way from catching of my logs. I’ve been making the templates for the three part of the wing ribs. Here’s the T/E template that is completed. It’s hard to see the pilot holes for the larger holes.

I’ve completed all the T/E ribs, 22 required. Took me about 2 hrs to make them all.

#### wiloows5050

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Work continues on this project slowly as my wife’s list of projects grows. Finished the L/E template and started the production of nose ribs, the only problem is I have a very limited supply of 1/4” plywood. I need to make 33 of these. It wood be easier it the grain wasn’t supposed to go at a 30 angle.

Completed nose rib template with pilot holes drilled for the holes.

First cut nose rub with only the smaller of the two holes drilled. I need to get a 2 1/4” hole saw to drill the other hole. It’s hard to see but the pilot hole for the larger hole is drilled.

Work continues on the center section template as I have to fill some areas as I took to much off. I use a mixture of sawdust and wood glue. It’s reasonably strong and doesn’t have a really long drying time.

#### wiloows5050

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This template is taking more work than the others. It was short so I glued a piece on 1/16 plywood on one end. I’ll need to fill some of the holes as they are off a little. I’ll make two of these. One with the center pilot holes and one with the center cut out.

#### wiloows5050

##### Well-Known Member
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First 13 nose ribs are complete. I had to get a 2 1/4” hole saw. The one I wanted was $50, I settled for the$15 one. I thought I only need to drill 33 holes.

The nose ribs waiting for the larger hole to be drilled.

The edges aren’t as clean as I’d like on the first so:

Taped the bottom and then drilled. Worked great.

First batch done, taped up and put in storage.

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#### wiloows5050

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This is the center wing rib template, the outsides are complete. All the holes are drilled for the corner points. Still need to cut the material out between the holes. When I’m done I’ll have three templates, one master, one with holes drilled and with the holes completely cut out. It’s hard to see but on the white one only some of the holes are elongated. This was done to get the holes drilled in the proper place.

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#### wiloows5050

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Now it’s time to cut out the middle. Since I’m not wanting to screw up cutting (straight lines) and have to sand the cut smooth heere a clever way to do it. I cut some short pieces of scrap 1/2” tube, the diameter of the holes.

Next I cut some small strips and nailed them in place tangent to the tubes.

Next I cut between the hole to remove the excess material. Then router’d the holes for a clean cut

Holes all done from front

this is the back side what the finished jig will look like. Only one problem, the smallest pieces came off during routing. I have to add some material back.

When the glue dries I’ll recut this area

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#### wiloows5050

##### Well-Known Member
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First of the center section ribs is complete

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#### wiloows5050

##### Well-Known Member
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It official I’ve run out of material for this project. I guess in could build the jig to assemble the ribs but it would just have to sit for awhile. In might be able to scrape up enough material to make a cap strip but not much motivation there. This stay at home is finally affecting my building.

Here’s the completed center section ribs and the parts laid out

#### wiloows5050

##### Well-Known Member
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Finally material for my projects! Quite a car load for \$1600.

Cutting the 1/4” ply for the remaining nose ribs.

The 25 remaining nose rib blanks. It feels good to be back at work.

#### wiloows5050

##### Well-Known Member
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All the wing rib nose ribs are complete. Still need to do the nose ribs for the elevator. Those are out of birch plywood. Had six rejects. 38 complete only need to square up the inside corners in the slot and were the capstrip meets.

#### wiloows5050

##### Well-Known Member
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Sometimes fate may dangle a carrot in front of you. I talked to a gentleman yesterday who has built several of these. He has several building mods that were never really published and the name and contact information I hope, for a gentleman who offers a complete kit of all the metal fixture. Hopefully I'll be able to get photos of the complete build process!. Score, just someone with first hand knowledge is going to be worth it's weight in airplane parts.

#### wiloows5050

##### Well-Known Member
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Cut the center section wing attachment brackets. They are a little oversized to allow me to clean up the edges. They were cut on my CNC plasma cutter. Took about 3 minutes to cut all 8 plates. Second photo shows the bevel from the shape of the flame.

#### wiloows5050

##### Well-Known Member
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Happy New year to everyone. I have changed from the wings to the tail. Long story which I will tell another time. Started on the nose rib on the horizontal stabilizer. Decided to cut it out of metal first then make a wood template.
Here’s the cut nose rib after I’ve cleaned up the edges.

Mounted on a 1/4 plywood to make a template for the router.

I cut a couple and took the best

First rib cut on outside, still need hole drilled.

Completed nose rib.

This whole endeavor came out better than I expected. The only area that I wasn’t happy with was the notch for the capstrips. The bandsaw blade was taking off small amounts of material with each cut. Started out at 2” and ended at 1.986. After I cleaned up the edges my metal template was a whopping.03 off! That was easily adjusted with a light pass on the deburring wheel.
New year resolution, try to keep up on builders logs

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#### wiloows5050

##### Well-Known Member
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I got to do something fun, I made capstrips, 1/8” . This is to fill the slot over the nose rib and spars.

#### wiloows5050

##### Well-Known Member
Log Member
This post is out of order. Got the center section ribs cut still need to drill the holes. The capstrips notched for the ribs.

Notched capstrips

All the part together with a sample spar block

All the completed parts

#### wiloows5050

##### Well-Known Member
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Got both the front and rear spars and the drag brace for the horizontal stabilizer planed to thickness. Still need to cut the end angle, lengths and the taper with bevel. The end is 1 1/4” the front of the spar is about 1/2 shorter than the rear, that the reason for the bevel cut.
First drag brace done

Completed drag brace

completed spars.
(In background front to back, Lee 7/8 N11, Airdrome Fokker DVII fuselage side, rear trusses for 2 hawker hurricanes and ME109 , all fuselages. What you can’t see S-4c wing parts, Fokker dr1 wing parts, second Lee N11 , DH-82a tiger moth restoration project. Plus my Warner 165 engine rebuild and two 4 cylinder engines.

#### wiloows5050

##### Well-Known Member
Log Member
Shop time for my projects has become hard to get. I got the birch blocks completed for the horizontal stabilizer. The small block are used to bolt the stabilizer braces to the stabilizer. The small of the two center blocks goes over the drag strut brace which is 1/2” tall.