I ended up not really using my cutting blocks. I decided to forego the flinging of metal shavings everywhere with the router, and used the Olfa knife method for these straight cuts. They turned out really well. I did use my cutting blocks as a drilling jig for the corner relief holes, and for lining up and drilling tooling holes for bending, so they weren't a total loss. Just for grins, I bent one of them to see how they'll turn out, and it was dimensionally perfect. I think I'm gettin' the hang of this. Next time I'll finish the bending and corrosion protection and get ready to assemble the flaps. I've ordered some piano hinge and nylon blocks from Aircraft Spruce, so it should all come together fairly easily. If you're reading this and thinking about a diving into a project like this, do it. It's not nearly the voodoo-chicken-bone black magic it appears to be at the onset. It's just cutting and bending metal. Don't get me wrong, you have to be careful and work to a pretty strict standard, but it's totally do-able.
Flap rib blanks ready for bending
Couldn't resist bending one to see how they'll come out. Looks good.
