Lower Motor Mounts

I just can't bring myself to chop up my plans for templates. I traced the parts onto notebook paper to be transfered to file folder cardstock so I'll have a more durable template.

Rough cutting the templates. The folder is plenty stiff, this shold work pretty good.

Final cut template - notebook paper and folder.

I taped the notebook paper to the folder to keep it from moving while I trimmed it.

Perfect template - you can JUST see the lines on the prints under the template.

Rough cutting the angle - a hacksaw is the easiest/most controllable method for me. I don't have a chopsaw so that isn't an option nor do I think the neighbors would appreciate the noise. A portaband would be handy here too.

Raw extrusion.

Using my card template.

The other half of the template. I'm glad I can visualize 3d objects in my head pretty easy - some of these shapes are kind of odd at first.

The card template - not 100% perfect, but definately functional.

The cutlines marked on the angle. Some of the angle was in pretty rought shape from shipping. I think Sonex should put the angle bundle in a tube like the spar caps to protect it from the shippers.

Rough cut - all on the bandsaw.

Filed and sanded. This first peice took about an hour. I'll definately get faster as I go along.

The other side - I took all the scratches off with 320grit sandpaper.

Note the nicely rounded corner. Gotta love the bastard file.

Pretty - I'm glad there aren't too may pieces like this.

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