Beginning with the master wing form, the shape for the nose rib was traced onto a piece of MDF. Using a washer with a 9/16" distance from the hole to the outside surface, I rolled it along the edge of the master form with a fine-point Sharpie in the center to create the flange, stopping short of the leading edge of the rib.
Once I had the first one created, I traced and cut the rough shape for the second piece, then bolted them together. I used a laminate trim bit to trim up to the first piece, creating an exact copy. Now we can sandwich several sheets of rough-cut aluminum between the MDF layers and route many identical nose ribs.
Started with the master form and traced the nose rib ahead of the forward spar.
Used the washer to trace the outline and create a 9/16" flange. Cut and sanded the first piece.
Traced and cut the second piece, routed the edge with a laminate bit to create a matching copy.
