Hi JJ,

Stand the cardboard vertically on the wing parallel to the chord, or on
the under side if you want a template of the bottom. Lay the marker on
the wing parallel to the span and perpendicular to the cardboard. Move
the marker in a chord wise direction to mark the cardboard. Trim and
repeat as necessary. You'll get a perfect template for that wing station.

I made saddles for my LS-6a almost 30 years ago by covering the wing
(top and bottom) with aluminum foil at the desired location. I then
covered the foil with plastic wrap, the plastic wrap with felt, and laid
up fiberglass over top of that. Made a perfectly fitted cuff (on one
wing, at least).

Good luck and let us know how it comes out.

Dan
5J

On 2/15/21 12:49 PM, John Johnson wrote:
You can make a profile template very quickly with a piece of cardboard,
a fat marker, and a pair of scissors.

Dan
5J

Hey Dan,
Not trying to sound any dumber than I am - but is there a technique to the cardboard and scissors approach? Or is it just a cycle of trimming and fitting until you get it right? I don't need a very accurate template for my case (need a sheet metal shop to make some tie down saddles for by DG300), I'm just thinking about how to get it right the first time.

thx, JJ