Brief Description: Rear Rib #1 and Aileron Gussets
More fabrication of 0.025" parts. Found a couple of simple-looking flat parts on Ailerons page 6W2 which I was able to draw out and cut relatively quickly. These appear to be part of the structural enhancements on the 650.
Rib #1 (part 65T4-6) is made from 0.025". I layed it out with side lengths and developed lengths for the bend brake rather that a form block. A partial form block was required to comple the bend on the end tab - shown in picture. This process yielded pretty accurate results. The largest deviation was in the overal length which measures 593.5mm rather than the 595mm shown in the plans for the form block length. Page 5 of the Zodiac Construction Manual specifies a tolerance of 1.5mm on parts (except spars and ribs). Also, based on it's length-wise orientation in the rudder there does not appear to be any critical structural or functional elements to this length.
Post assembly note: To ensure the mininum 10mm rivet line edge distance can be maintained - on the rib flanges and lower edges of the rear skin - I would add an extra 3mm to the rib flanges. This is necessary to compensate for the skin edges mating at the tangent line of the rib flange radii as opposed to the bottom face of the rib.