After further reflection and prodding from Dan Melton (#869), I have cut my massive, full length lightening hole jig into 3 seperate pieces. I then had to recess more jig pin hardware holes into the backer plates of the center and aft portions.
I also created what amounts to a wooden tip for a rivet set. This will be used to flatten the rib after flanging the lightening holes. Others have used similar things, but this one is sized for the set. I used a 2" long piece of a 7/8" hardwood dowel from Home Depot as the body. I then bored a 1/2" hole using a forstener bit to a depth of 1". I knew that 7/8" was a tad large for in between the lightnening hole flange and the rib flange, so I chucked the set/tip assembly in the drill press, grabbed my file, and pared it down a touch. Should work great. Full report "soon".
