So, part of the problem with doing a plans build is how to bend long pieces of metal. While most parts are under 4’, there are quite a few in the 7-8’ range.
From some notes I made a while back:
Vertical Tail
4.5ft
C75R2-1 Rudder Spar 52” 0.04 92.98
C75R3-1 Rudder Skin 53” 0.016 54.06 (2x)
Horizontal Tail
8’
C75T1-5 Stabilizer Rear Spar 94” 0.032 98.71
C75T2-4 Stabilizer Skin 96.1” 0.025 252.21
Flaperons
6’
C75A1-4 I/B Flaperon Spar 72” 0.032 53.37 (2x)
C75A1-9 Flaperon Skin O/B 63.7” 0.016 $127.03 (2x)
7’
C75A1-8 Flaperon Skin I/B 74.2” 0.016 $127.03 (2x)
Wings
7’
C75W4-4 I/B Rear Channel 79 0.032 124.62 (2x)
C75W4-7 Top Rear Channel Angle 76 0.04 17.49 (2x)
C75W5-1 I/B Nose Skin 70.1 0.025 165.63 (2x)
C75W6-3 I/B Trailing Edge Skin 83 0.020 98.85 (2x)
All in, we’re looking at 5-6k roughly. I imagine this could cut into that somewhat, particularly since I’d have to order large sheets for the skins.
Now, I could buy an entry-level 8’ automotive sheet metal brake for about 1k, I might be able to build my own as well. The question is: how much would I really save with each possible avenue? With such large pieces, how much would it cost if I botch the fabrication and have to order a new sheet?!