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>> 2)  If I make [face sheets] myself, is there a better way than roughing
it out on a bandsaw, using a bench sander to final shape, and
painstakingly filing the
edges for smoothness? <<

Heck yes!  Rough them out on a bandsaw, use a bench sander to final
shape, then polish the edges for smoothness with a Schotchbrite (tm) wheel
on your bench grinder.  A file? Sheesh... WAY too much work!

You can also get Scotchbrite (tm) tools of various shapes for drill motors
or die grinders.  These things do miracles on aluminum.


 - Doug Dodson
   Glasair II-S FT
   Flight Test Engineer, CFI-A,G
   Baby Dragon IF1 Race Team
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LML website:   http://www.olsusa.com/Users/Mkaye/maillist.html
Builders' Bookstore:   http://www.buildersbooks.com/lancair

Please send your photos and drawings to marvkaye@olsusa.com.
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