I was inspired to use a rib jig that made building the ribs a 'one step process'. The ability to glue and clamp the gussets to both sides of the 1/4 x 1/4 spruce made for a 40 minute job per rib once the system was established.
Had to change it a little towards the rear as it was too narrow and risked breaking. So 4 gussets get glued (duct tape underneath) and clamped on one side only, then the reverse side is done when the rib is removed from the jig.
Cut the channels with a router guided using straight edges and curved over the top. 8mm dia bit (approx 5/16") set to a depth of 4mm (approx 5/32")
Used a jigsaw to cut out the access areas and then screwed in 90mm x 35mm timber lengths underneath to keep it rigid as well as elevating the jig from the surrounding surface.
Pre-cutting all the spruce to length took about an hour and now sits labelled and ready to put straight in the jig.
