After several evenings of cutting, the aluminum parts have been cut out.
No Fancy saw to do this. My hacksaw has an angle blade position, by using that angle was able to completely cut the aluminum parts out. 1/8" Thick 5052 aluminum, my hands are sore. Not used to that kind of work! Cutting torch can only cut mild steel. Do have a skill saw with a diablo blade for cutting aluminum, too many curves to use it.
Drilled holes to get the blade inside for the spar locations. You can see all six of the spar locations. Six are needed if using just the cardstock and no carbon or fiberglass.
Parts weighed in at first 1lb 5.6oz [.708kg]. Weight after drilling a few lightening holes 15.5oz [.439kg].
In the center of these will be a balsa wood rib 3/16" thick. Both wing spars will "Plug" into the aluminum and the balsa wood to lock everything into place.
Cardstock ribs have been laminated to the backing from a couple of desk top calendars.
Next step will be to build and then fit the ribs and spars to the center power skid (aluminum parts). Once spars fit the balsa and aluminum parts, the power skid will be welded.
Could have used thinner aluminum and TIG welding, much better at MIG welding aluminum. Decided to use the 1/8" and wire feed weld it.
Will be making the wingtip ends using solid balsa and 1/4" thick basswood. Need solid mount for the rudders. Will be carving them once the wood is glued together.
Mike