Current Progress

March 16 2025 - 2.5hrs - 4731.0 total. Made up remaining 3 intercostals and 14 gussets for between ribs # 4 & 5 port. Spent some time looking at the plans trying to verify the intercostals on the low numbered ribs on the SB side. Determined there is a set of very large (1/2" X 1") going from rib #1 through to #5 on the SB side. Started making those up. They will require custom made gussets.
March 17 2025 - 1.0hrs - 4732.0 total. Made up the two custom gussets for the large intercostal between ribs #4 & 5 SB
March 20 2025 - 3.5hrs - 4735.5 total. Glued in the large intercoastal and two gussets between ribs 4 & 5 SB. Glued in 5 of the 9 intercostals between ribs 4 & 5 port, including their 10 gussets. Made up the 8 intercostals for between ribs 15 & 16 SB. Traced, cut out, and sanded to shape 22 more gusset blanks.
March 21 2025 - 3.5hrs - 4737.0 total. Cut notches in a batch of gusset blanks with table saw. Made up 16 gussets for between ribs 15 & 16 SB. Made up ten shim and reinforcement strips for around rib #16 SB and glued them in place. Glued in the 8 intercostals and 16 gussets between ribs 15 & 16 SB. Used small blob of left over epoxy to glue in one more intercostal and two gussets between ribs 4 & 5 port.
March 22 2025 - 2.0hrs - 4739.0 total. Spent about two hours (not counted) studying the plans concerning intercostals inboard of Rib #5 SB. There's a lot going on there, between the gear and the radiator, and its taking some interpretation to be sure I don't miss something. Also, installing the ribs has been pretty straight forward for a while, but now it's getting complicated again. The last two or three ribs don't fit on the spar so THE SPAR will need to be trimmed to allow them to fit. Most frightening because of potential alignment issues. Will take some planning and thinking before that gets done. In the mean time today, I made up three intercostals and six gussets for between ribs 4 &5 SB. Measured and marked their locations on the ribs. Aligned rib #17 SB and tacked in place with 5 minute epoxy.

Nine intercostals and 18 gussets ready to be glued in between Ribs #4 & 5 port. (including in front of the spar)

Large intercostal and gussets glued, three regular and their six gussets ready to be glued in between ribs #4 &5 SB

Tacking rib # 17 SB in place with five minute epoxy

Large intercostal and gussets glued, three regular and their six gussets ready to be glued in between ribs #4 &5 SB

Tacking rib # 17 SB in place with five minute epoxy

March 23 2025 - 3.5hrs - 4742.5 total. Made up the ten shim and reinforcement pieces for around rib #17 SB and glued in place. Marked locations for intercostals on rib # 17 SB. Glued in two more intercostals and 4 gussets between ribs 4 & 5 port.
March 24 2025 - 2.0hrs - 4744.5 total. Made up eight intercostals and sixteen gussets to go between ribs # 16 & 17 SB. Ready to be glued in.
March 25 2025 - 2.0hrs - 4746.5 total. Glued in the eight intercostals and sixteen gussets between ribs # 16 & 17 SB. Glued in three intercostals and six gussets between ribs 4 & 5 SB. Glued in last remaining intercostal and two gussets between rib # 4 & 5 port.
March 26 2025 - 2.5hrs - 4749.0 total. Aligned rib # 18 SB and tacked in place with five minute epoxy. After it cured, sanded epoxy down and made up ten shim and reinforcement strips for it. The intercostals will be different here between ribs 17 & 18 as this is where the pitot tube mounts.
March 27 2025 - 3.0hrs - 4752.0 total. Glued in the ten shim and reinforcement strips on rib #18 SB. Made up the eight upper intercostals and 16 gussets for them. Made two standard intercostals with four gussets for lower surface and two larger (1/4" x 1") intercostals and customized gussets for them. Glued in the two intercostals and four gussets between ribs 17 & 18 that are in front of the spar.
March 28 2025 - 1.0hrs - 4753.0 total. Made up another intercostal for between rib #17 & 18, along with two gussets. Looked at area on spar between ribs # 1 & 4 with eye towards getting that entire area, including the large hole for the gear pintal, sealed with epoxy.
March 29 2025 - 2.5hrs - 4755.5 total. Glued in seven intercostals and fourteen gussets between ribs 17 & 18 SB. Aligned rib #19 SB and tacked in place with five minute epoxy. Made up bracing for pitot tube base.

Eight intercostals and sixteen gussets ready to be glued in between ribs 16 & 17 SB

Ten shim and reinforcement strips for rib #18 SB

Eight intercostals and sixteen gussets ready to be glued in between ribs 16 & 17 SB

Rib # 19 SB being tacked in place. Dry fitting two braces for pitot base

Eight intercostals and sixteen gussets ready to be glued in between ribs 16 & 17 SB

Rib # 19 SB being tacked in place. Dry fitting two braces for pitot base

March 30 2025 - 2.0hrs - 4757.5 total. Sanded down five minute epoxy around rib # 19 SB. Space around rib is very small so can't make normal set of reinforcement strips. Instead made up a set of five. Also made up six intercostals and twelve gussets for between ribs 18 & 19.
March 31 2025 - 1.0hrs - 4758.5 total. Glued in the reinforcement strips around rib # 19 SB. Glued in the bracing for the pitot tube baseplate. Glued two intercostals and four gussets between ribs 18 & 19 SB.
***Going to be unable to work on the project for about two weeks or so. Keep checking back - I might be able to get back to it sooner.***

April 20 2025 - 2.0hrs - 4760.5 total. Glued in last four intercostals and eight gussets between ribs 18 and 19 SB. Removed jig support from under SB end of wing and braced so that I can start shaping the end of the spar to receive the last three ribs on that side. They don't fit on the spar and the plans say to trim the spar to fit the ribs, rather than the other way around.
April 21 2025 - 2.0hrs - 4762.5 total. Sanded down tip of SB spar so that the last three ribs fit. Wasn't as bad as I had expected. Had to do a little cleanup on the spar openings in the ribs themselves as the were sort of rough cut. Checked alignment with laser level and they can be aligned now. Haven't done it yet as I need to check the plans and make sure I'm doing things in the correct order. For the last year or more its been very obvious what needs to be done next - Cap strips and glue on the ribs. Now that those tasks are basically done, its getting complex again!
April 25 2025 - 1.5hrs - 4764.0 total. Aligned rib # 20SB and tacked it in with 5 minute epoxy. After it dried I notice it looked a little off. Rechecked with laser and its exactly where the plans say, but it about 1/4" off the rest of the wing. The last three ribs are so small that the slightest measurements seem to be more critical. Went back over plans and will just align it with the rest of the wing. I'll need to cut it loose and re-align. The last two ribs are 1/8in ply and call out for 1/8in ply cap strips. Tried to work that out and will just put 1/4in on there and sand them down as needed.

Bruce's Spitfire

Current Progress Status and Updates

Nine intercostals and 18 gussets ready to be glued in between Ribs #4 & 5 port. (including in front of the spar)

Large intercostal and gussets glued, three regular and their six gussets ready to be glued in between ribs #4 &5 SB

Large intercostal and gussets glued, three regular and their six gussets ready to be glued in between ribs #4 &5 SB

Large intercostal and gussets glued, three regular and their six gussets ready to be glued in between ribs #4 &5 SB

Large intercostal and gussets glued, three regular and their six gussets ready to be glued in between ribs #4 &5 SB

Large intercostal and gussets glued, three regular and their six gussets ready to be glued in between ribs #4 &5 SB

Tacking rib # 17 SB in place with five minute epoxy

Large intercostal and gussets glued, three regular and their six gussets ready to be glued in between ribs #4 &5 SB

Tacking rib # 17 SB in place with five minute epoxy

Eight intercostals and sixteen gussets ready to be glued in between ribs 16 & 17 SB

Eight intercostals and sixteen gussets ready to be glued in between ribs 16 & 17 SB

Eight intercostals and sixteen gussets ready to be glued in between ribs 16 & 17 SB

Ten shim and reinforcement strips for rib #18 SB

Eight intercostals and sixteen gussets ready to be glued in between ribs 16 & 17 SB

Eight intercostals and sixteen gussets ready to be glued in between ribs 16 & 17 SB

Rib # 19 SB being tacked in place. Dry fitting two braces for pitot base

Eight intercostals and sixteen gussets ready to be glued in between ribs 16 & 17 SB

Rib # 19 SB being tacked in place. Dry fitting two braces for pitot base

Six intercostals and twelve gussets ready to be glued in between ribs 18 & 19 SB. Also five shim/reinforcement strips for around #19

Overall view of wing current progress

Starboard wing progress

Starboard wing progress

Ribs # 20, 21 & 22 being dry fit on SB end of spar

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