Made a copy of the aileron nose rib from the plans and checked to make sure it matched. Then cut out the nose rib from the copy and glued the pattern to 3/4" MDF. Then I drilled 1/4" holes in the grooves between the flanges and cut the pattern out with the bandsaw and sanded to the line. Between the flanges required some clean up with a file. Then i used a 1/4" pattern bit that fit into the slots between the flanges and cut a matching one from another piece of 3/4" MDF.
