October 6, 2007
Ribs
All the forward ribs that required gussets... 8 total, 4 on each wing.  Here they are drilled out to #40's.
After drilling to 30's we deburred and lightly primed the gussets.
The head of the riveter would not sit flush against the rivet because it was rubbing on the rib flange. Used this spacer to assist in placing the rivet.
Gussets all riveted on the forward ribs.  There are a lot of holes in these gussets!  A little time consuming.
With the forward ribs complete, it was now time to start the aft ribs. There are 10 of them we must trim, and 8 of them require the gussets.
Used my tool for finding the correct cut out for each rib.
Duplicating the correct cut out on the rib itself with the tool we made.
My marker had a leaking problem?? Oh' well, my dad and I had a nice assembly line going. I was marking all the parts while he was on the bandsaw cutting them off. 
There are 2 aft ribs you must do something a little different. Rib # 5 you need to trim it like the rest, but you do not add a gusset to it. Rib # 1 Right, you need to take the aft flange off and put another back on at a different location. You will see what I mean further down.. 
Speaking of the devil! Here is rib # 1 Right!!  You make this angle (If you have been following my progress from day one, you know I already had this angle made because the first 3-4 months of this project was making all the angle and channel parts) which turns into the flange, while you chop off the current flange.  Your main objective is to make this "1"  rib a little shorter than the others. (There is a 3/16" plate that mounts on the rear spar causing this rib to be too long in it's current state.)
The ribs come with the aft flange holes already predrilled. Since this one is going to be Toast here in a second, I wanted to duplicate those holes in the angle piece I made.  Just clamped it in place and drilled.
The plans want you to have your new flange so far from the end of the aft  rib. It was kind of hard to measure, so we just added a piece of aluminum the same thickness as the plate that fits on the front of the rear spar.  That should give us just the right distance.!
After finding the right spot, we drilled and cleco'd the angle (or new flange) to it's new home. We cut the old flange off with the bandsaw. Then we riveted the flange on for good!
Dad cut all the 10 aft rib trimmings on the bandsaw.. Only thing left now is to drill and rivet the gussets on. Which hopefully will be done tomorrow!