Tightened up the blank forms a bit on the band saw and match drilled 1/4" tooling holes using the form block as a locator. Traced a rough blank form on a sheet of 0.020" six times then cut out using air shears and hand snips. Air shear not working as smoothly and effortlessly as when they were new. Could they be suffering from "Made in China" syndrome?
Drilled the four 1/4" corner relief holes on the drill press. Cut sandwich just outside of the finished blank profile with bandsaw. Brought edges smoothly up to the profile lines with belt and disc sanders. The resulting blanks came out smooth and identical.
6/25/11 Update: In addtion to the new form block I will also have to make new blanks.
Observation: The rib ends must attach to the spars with clearance to the doublers as shown in a couple of detail views and illustrated in the Asm Gde. However, this profile and corresponding dimensions are not detailed on the drawing. I will measure the distance between the upper and lower doublers on each spar to ensure the rib end flanges are sized accordingly.
