I was having a hard time getting good results on flanging the nose rib lightening holes. Finally decided to make a separate die and plug set instead on using the hole in the form. Made the die out of 3/4 MDF and used a 45 degree router bit to make a chamfer on the edge.
Had to make several plugs out of hardwood until I found the right one to give me a good 1/4" flange on the hole. Once I got the right plug it took only about 30 minutes to do all the ribs.
