For anyone else who might be in the same predicament, the fine folks at Homebuilt Airplanes came up with a couple more sources. B&D International carries 5′ x 5′ sheets of Finnish birch aircraft plywood, and will cut and ship UPS. Boulter doesn’t carry as wide a variety, but might be good if you’re closer to the east coast than the west.
The price at B&D is higher than Aircraft Spruce. If you price it by the square foot, it’s not terribly higher. 13%, on the 1/8″ sheet I need. Not terrible.
The plans and BOM call for plywood spar webs, cross-cut, 60″ long. The webs are butt-spliced mid-wing, with what seem to me to be fairly narrow blocks of spruce on either side.
Problem is, you can’t buy 60″ wide sheets of aircraft plywood in the US. Aircraft Spruce has ONE size, and not a size I need. Everything else I’ve found is in 48″ wide sheets. And since the web needs to be crosscut, it’s not as simple as just buying a 4′ x 8′ sheet. I’ve contacted Fisher Flying Products as well as another supplier in Canada. Fisher’s tab will be roughly $340, the other place was pretty reasonable for the plywood but wanted over $500 for crating and shipping. To put that in perspective, ACS will sell me the plywood I need for about $100, delivered.
The question is, can I make 48″ long spar webs work in a way that is at least as good, or preferably stonger and better, than the original design? I am no engineer. Especially a mechanical engineer. I’m certainly not qualified to make such a call. Fortunately, I have someone local who is an engineer, and is qualified to help make that decision and recommend another way to do it — if there is one. I’ll be taking the wing plans to the February EAA chapter meeting to go over them with him and see what we can figure out.
If that doesn’t work out, Spruce does sell 5/32 ply in 61″ x 61″ sheets. The spar webs are specified as 1/8″ for the main spar, and 1/16″ for the rear spar. I could just make both webs 5/32 with a slight weight penalty. The plywood would weigh 3 to 5 pounds more, but I’d probably also need to trim 1/32 to 3/32 from the spruce stiffeners, so that might make up for some of it. Again, I’ll need to consult with a real engineer to see if that wold work or not. Ending up with a plane that’s a couple pounds heavier but significantly stronger is OK. Ending up with a plane that is in any way less strong or less safe is absolutely not. And if the ribs need to be modified a little to clear a beefier spar — I’m OK with that.