Tracing the outline of the old wing onto cardboard and then cutting out the shape to make a template to trace it onto the new wing is an easy task.
But: the challenge is where to tape the template onto the new wing? Not only is the new wing wider than the old, but I also want to adjust the finished width to add in an extra 6mm or so.
So Button's cunning plan of establishing a datum line down the wing is a good one. I can then work off that to establish a reference from which I can displace the template by a consistent amount.
The last challenge is to ensure that the datum line is in the same relative position on both wings.
That's where Simon's recommendation of using the 3D printer to make a jig comes in.
Here's the plan:
1. Print out a simple pantograph that holds a pen at an adjustable distance from a base edge
2. Put a stripe of masking tape down the old wing where I want the datum line to go
3. Run the pantograph base down the outer edge of the wing, marking the datum line along the masking tape at a fixed distance from the outer edge.
3. Tape a strip of heavyweight paper with the edge aligned to the datum line on the old wing
4. Trace out the inner edge of the old wing onto the paper
6. Cut along the profile line to provide a template
7. Run the pantograph along the new wing to replicate datum line on the old wing
8. Adjust the pantograph to add the extra width
I want and run another datum line down the new wing
9. Use the new datum line as a base line for the template and transfer the required profile to the new wing
10. Take my trusty disc cutter and trim off the unwanted bit of wing
Hopefully I won't require step 11
11. Ring up Sid Watson and ask him to make me another wing
More news at the weekend, I have to do some actual work for a few days...
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