Each Rib needs a little gusset plate. Starting the parts.
A
B
Ligthening Holes In Ribs
Dan took on the task of using the fly cutter to cut out the lighten holes in all the ribs. Dan mentioned he clamped and braced one side of the rib against the post of the drill press. (Make sure no clothing can get caught in the fly cutter.)
Router Rib Shape
We cut out the ribs with the electric shears, but it cannot get the bend corners. We deceded to use a router for the final rib shape.
Here Dan is creating a form block to use on the router. Using the washer trick from the Sonex class to get the flange distance. Note the angle perpendicular to the curve at the corner cut outs. This makes the flange correct once you bend it over.
Here is a rib in the form block after the router:
Here is a top of the form block off:
Here is a stack of routered ribs:
