As soon as I was done with the rear HS spar, I immediately started on the front HS spar. It took me about 20 minutes of reading and re-reading the instructions, as well as staring blankly at drawing 3...trying to figure out exactly what goes where and how. It's spelled out, but really poorly and incredibly fragmented.
Anyway, I started by finding the center of the top 1/8" thick aluminum angle flange, measuring out, and cutting the tongues and angle flanges. That was easier than I thought. With a hack saw, I made a rough cut; then I used the bench grinder to do an initial smoothing; then I used the vixen file; then I used a medium-grit ScotchBrite wheel in my die grinder; then I used a 7447 ScotchBrite hand pad. After all that, it looks great. I still have to radius everything and trim, but the initial big cuts are complete. All that for one little (but critical) part!
Here you can see the part with the scrap from the cutouts.
