Picked up a 34" x 48" sheet of 6061-T6 today from Metal Supermarkets. This company will provide materials in the sizes needed at just a slight $/qty penalty over full sheets or lengths. For an extra $15 I could have purchased a half sheet (6' long) from Trident but that would be way more that I'll need.
With the experience of forming three rudder nose ribs behind me these 6T1-1 end ribs were relatively quick and easy. To form material down into crimp detents I tapped over them with a length of 1/2" diameter hardwood dowel using a mallet. Did final straightening with the crimping pliers.
Note: I cut 18mm notches off the bottom of each rib flange as shown in drawing detail 6T1-1. However, pages 10-12 of section 6T2A in the Assembly Guide show how to mark and cut these notches based on thier specific fits to the stabilizer. Noting that other builders had also pre-cut these notch I'm assuming this will not be an issue.
Tip: The design and manufacturing of parts are usually correlated to - if not dependent on - the assembly processes. Make sure your "product and manufacturing engineers" are in constant communication with your "process engineer" :-)
