Tonight I was prepping for the arrival of the aluminum sheets tomorrow. I made the first form for the nose ribs. Using the master form block, I traced out the nose rib onto the MDF and then used a large pencil to scribe the 9/16" flange. Used a band saw to cut out the first block and then used the router table with a laminate bit to make the second form. This is definitely the method I'm going to use to cut the nose ribs. Spent the time making the first form block the way I want it and the router will make the rest to match. Don't have a solid plan for the lightening holes yet. My drill press has a minimum speed of 700 rpm so using a fly cutter isn't going to work. Tentavilty, I am planning on using a traditionall wood hole bit for the MDF and then making a rough cut into the aluminum with a rotary tool. Then see how the router does on lightening holes.
