Cut out both forms for right rear rib #8. A usual, layed first cutout on top of blank MDF, drilled center holes for lightening holes through both MDF boards (also used as alignement holes for two form halves as well as additional clamping for forming). Traced one from the other as usual. Routered edges of forms with 1/8" roundover, measured and layed out crimp recesses. Placed right half on blank .025 6061-T6 sheet aluminum. drilled through center holes into worktable. Then traced 19mm around form with Sharpie marker and 19mm roller spacer. marked corners for 3/16 relief holes. Cut out template and other extraneous pieces of rib blank. Drilled relief holes. Clamped rib blank in between two forms with center bolts thorugh 4 lightening holes centers. Started with little crimps and crimp recess locations. hit flanges with rubber mallet over 30 degrees. Back with crimping tool then over another 30 degrees, then crimper again and finally close last 30 degrees with mallet. close crimps more with hammer on rounded 3/4 inch wode strip of oak. Mallet over end flanges to 90 degrees. Took out of forms. Fine tuned til flat on worktable with crimper and hand seemer. Mostly crimper unless the angle is most drastically off. Usually lines flat with just a small amount of work with crimper.
Next rib went to drill press where it gets the 4 lightening holes cut out with a flycutter. Then the holes were deburred with a 45 degree swivel deburring tool, and then off to be flanged with flangng tools borrowed from Geoff Heap. He had 115mm, 95mm, and 65mm flanging tools, but the 65mm flange tool only had the female part. Flanged two 115mm and the one 95mm hole. The 65mm flange male part is the next task.
