Hello Alan and welcome to RCSB/  David is right,take a look at Lee's thread, and there are a couple others going on now too.  But my first thought was the same as your last sentance - make a full size pattern and pull the wire around that - I would think it would not have to be fully formed to the curve but that fixing it to the TE of the ribs would hold it in place.

And he is also correct about becoming a site supporter - it is amazing how much help you will get and how many friends you will make.

http://www.rcscalebuilder.com/page_display.asp?pid=5

Howdy Alan,

  Just a thought . I have used three pegs set in line into a wooden board. Wire is then pulled through with a set of grips and pushed from behind as not to pull the bend out. The closer the pegs are together, the tighter the curve. Trial and error will tell me how for apart to make the pegs to achieve a proper curve. Industrial benders work in this fashion utilizing rollers. Hope this helps.

                                                           James

Hi Alan,

I found the only way to bend the wire was by hand, as I'm sure you've found out, It's piano wire and very tough, if you try to use formers it just springs back out and is really difficult to judge.

Just bend it with your hands and keep comparing it with the plans, you need to get a good shape because you don't want it under any tension when fitted to the wooden parts.

Lee