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It turned out that the CNC laser cutting machine at the fablab has unacceptable tolerances on one axis. They are about to put another one in service, it is already on the shop floor but it is missing the air filtering plumbing. In the meantime, I re-drew the jig so that it can be used to both cut th...

I ended up joining the local fablab. Their capabilities are limited (no router / milling machine) but they have a laser cut. They only had cardboard handy so I did a trial cut in cardboard; I'm not sure about the tolerances but the Falco manual calls for 0.1mm anyways. Apparently we can't attach pic...

I got some quotes from local shops to cut up the jigs and it's not going to fly. Around 100e apiece. Maybe the first project will be to set up a CNC.

Thanks Pete,I looked it up and indeed here it is: https://www.thingiverse.com/thing:3271229 Very impressive & detailed work. I'm going to go step by step and try building jigs in CAD, starting with the stabilizer ribs. I started a different topic to share the progress in case anyone is interested: h...

Dear all, Fair warning: I have 0 experience with wood construction. My first goal for our Falco project is to build a jig that would allow an 8 year old to assemble the stabilizer rib at station 0. I'm thinking of carving this jig in plastic or wood with a CNC: https://a360.co/2UHscdH (the web shari...

Thanks Alfred. I'll work on the rib jigs and will report on the progress. I'm going to move some drawings to Fusion 360; I'll happily share the work if anyone is interested. Best William PS: I was about to attach a screenshot but it looks like the file upload size limit is set to a very low value?

Alfred, thanks for your reply. Glad to hear that the kits are still available. Looking forward to seeing that new gearbox! We would like to build the ribs (vs. purchasing them). It seems that the logical first step is to grind our teeth by picking a tail rib and building its jig, and then maybe asse...

Dear all, We're a little family of 5, currently living in France after 7 years in the US. I got my private licence in 2014 in the Bay Area and I kept working on my ratings (IR, multi, commercial) while taking trips with the family. In 2015, we got an Aztec that we refurbished in Montana (I spent 9 w...