On Sep 26, 1:01*pm, " wrote:

The point here is that while bending a flange may have to be learned,
it is a skill that is used over and over again for ANY flange. * -R.S.Hoover

Pictures and some more words of yours truly bending such a flange:

http://users.lmi.net/~ryoung/2006/11...ilders-of.html

I find the use of a scrap of 1/4" softwood ply to be very, very
helpful in distributing the blows - NOT door skin, and NOT anything
any thicker - if it's too thick it'll form a hard spot at the edge of
the ply, and put kinks in.

I learned this technigue from a video of Dave Thatcher of CX-4 fame
demonstrating this with a folding table, 2 ea 2X4s and a rubber mallet
at Sun and Fun a few years ago.

Regarding all metal VW powered single place designs, the BK1 is
looking really nice, but plans aren't available yet. Bruce has done so
much of his own design and engineering that it's not fair, IMHO to
call it "an upgraded Hummel".

Plans for the CX-4 and the Hummelbird Ultracruiser Plus ARE available,
and there are several builder completed airplanes flying for each. I
have plans for the Teenie Two...and that's one of the reasons I'm
building an Ultracruiser Plus. The Ultracruiser Plus has the added
benefit of easily accomodating a flywheel drive prop hub without any
airframe changes due to it's bed mount for the engine, but it's a low
and slow, fat winged ultralight on steroids, and doesn't suit every
mission profile.