Rolling Leading Edge

Like the trailing edge, rolling the leading edge wasn't a task I was looking forward to. It's another one of the many tasks required to build a plane that requires finesse, technique, experience and a little black magic all of which I'm lacking. And which can royally screw up the rudder if done incorrectly. The previous night I created the profile templates from thin foam board. I perused the VAF Forum trying to cue on various techniques and pitfalls and reviewed Section 5 yet again. I copied a technique off the forum utilizing a 1" PVC pipe with two 9/16" sockets JB Welded in each end that I could turn with a 3/8" ratchet. Seemed preferable and more controllable then the vice grip on a pipe technique. A quick trip to Harbor Freight and Ace got me the required parts. I started out the with small flanges first at the top since access is limited to one side only. Working slowly I was able to manipulate the sheet metal to the required curve. There was some spring-back to make the holes match but the profile was very close to the template. The middle flange section was much more difficult because it was so much bigger. I struggled for hours trying to make the section curve correctly, match the template, keep spring back to a minimum, all while trying not to crease the sheet metal at the spar or damage anything. In the end I was less then fully successful. Despite my best efforts I couldn't make the metal curve to match the template for that section very well. Access is just too limited with the opposing curved flange in the way. A fair amount of force is also needed to bring the flange holes together to cleco. Not sure what the secret is but I haven't discovered it yet. I know the whole point is to create a leading edge that fits neatly between the overhang along the hinge line of the vertical stabilizer. It's unclear what the ramifications will be fit and appearance wise having a leading edge that differs about 0.2" from the template. 10,000 other people have built and flown RVs and had to do the same tasks so I'll keep at it. Most of them have never built a plane either. Tomorrow I'll tackle the lower flanges.