On the Tiger Moth, I’ve had the students do the “gross” or production work, but I do the “fine” or detail type work. So now that we’ve got the basic wing structure done, it’s time to add the rounded leading edge of the wing.

First, I add an upper and lower “false” spar to the leading edge. Each false spar runs the full length of the wing and needs to be straight. I’ve epoxy’d the false spars to the full length ribs and the false ribs (half size ribs).

Clamping the ribs to the main spar.

Next comes preparation for the leading edge by adding the nose caps.

Adding the a nose cap.

Adding more nose caps.

Once the nose caps are installed, the tricky part starts – wrapping 1/16″ Finnish plywood (don’t break or crack!) carefully over the leading edge. I’ve soaked the plywood to help bend but before committing myself, I double check layout.

Laying out the leading edge ply.

Wrapping the leading edge.

Things look good so far, so now  it’s time to mix up the epoxy.

Mixing up some T-88.

Applying epoxy to the nose caps.

Don stapling the leading edge to upper false spar.

Clamping the leading edge ply.

I stapled the plywood to the upper and lower false spars prior to clamping. After the epoxy has set (the next time I come out to the airport!) I pull all the staples and sand/finish the tiny holes.

I’m moving smartly, but carefully, along because the epoxy starts to harden up. Again, you can’t have too many clamps for a job like this!

Clamping the underside of the leading edge ply.

A lot of the detail work on the wing is solo work, but when I do the leading edge, Leslie also helps with the layout, epoxy and clamping.

Leslie clamping the leading edge.

There’s still a lot more detail work yet to be done on the wing however!