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How did a homebuilder construct the wing using Bede's Panel-Rib system?

Short answer

The wing was built up in sections that slid over a tubular spar and were fixed to each other where they met. The bonded panels created a liquid-tight joint, unlike conventional riveted systems. Even so, leaks appeared from faulty sealing and wing flexing.

How did a homebuilder construct the wing using Bede's Panel-Rib system?
¿Cómo construía un aficionado el ala con el sistema Panel-Rib de Bede?

A kit for those who didn't know how to build

Jim Bede conceived the BD-4 as one of the world's first true "kitplanes." The idea was that people with little or no prior manufacturing experience would start with a complete set of plans and end up with a simple bolt-together operation.

The wing, section by section over the spar

The wing was built up progressively: sections slid together over the tubular spar and were fixed to each other where they met. Since the panels were bonded, they formed a liquid-tight joint, unlike conventional systems that used rivets. Even so, leaks inevitably appeared due to issues such as poorly done sealing and the wing's natural flexing.

Flat sheet metal and plans still available

For the rest of the structure, aluminum angle brackets bolted together formed a truss frame. There were few curved surfaces, and most of the fuselage was made of flat aluminum sheet. In 2017 the aircraft was still available as plans for amateur construction, offered by Bedecorp, of Medina, Ohio.

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