[Guest]

Rather than trying to hog out the old spar, why not drill out matching holes on either half, at the top and bottom of the original spar blades, insert CF rod or tube to match the hole.

If this was originally a two-piece wing that butt-fits, I'd also sand the inner ribs to remove anything else like covering material and then applying a good but light coat of epoxy. Makes it a one-piece wing but you have all the strength that you'll ever need.

If this is where the wing halves fit against the cabin exterior, you'll also have to put holes and bracing in the fuselage to transfer the stresses to the fuselage. Also, make the struts functinal and effective in up and down pressures.

Jim, does this sound like a good solution? Yes, the use of a vertical or hoizontal drill press is recommended as well as a jig to ensure that the four holes are lined up.

[4*60]

What I did in a similar situation, not being very energetic. I cut slots in front of and behind the spar and inserted new "joiners" to the 2nd ribs, with LOTS of epoxy and tight to the original spar. Small joiner added at the rear and lots of epoxy on the ribs. I believe I did one half neatly and then when cured covered everyhtin in epoxy and joined it and held it together as normal It was strong enough and there was no cutting into the covering.
Today's epoxies stick to wood pretty good. I would consider using some dowel (additional) in the holes in the ribs through the 2 first ribs in each side also.