Brief Description: My Formblock System - A how to (part 1)
I built my system for repeatability. Every rib is just like the last. As you can see in my log, I have two sets of forming blocks for each unique rib. I have a shaping block for the router table and lightening hole block for the hole flanges. If you decide to Bob Stick the flanges, then you won't need that second set. But since all the blocks are formed with a router table, I believe that less time is spent (versus the Bob Stick) as each rib can have its lightening holes flanged with just a "umph" on the press. And of course, as with any task, the setup is everything.
NOTE: My Master Rib Form (created from the #7 mylar) has bushings at all my jig pin locations. Any extra jig pins you decide to drill must not interfere with the Rib-to-Spar attachment angles or Lightening Hole Flanges. And also allow for bolthead/washer countersink room on the backside of the block. My Lightening Hole center locations do not have bushings on the Master Rib Form. I wish I had put some in, but I never really noticed any issue with it though.
NOTE: All my drilling was performed with a drill press and the form clamped to the table. The extra time spent here will pay off later.
