Brief Description: Master form bushings, backer form, router jig
I drilled 5/16 inch holes for the jig pin locations and center of the lightening holes. I inserted a brass bushing with an inside diameter of 1/4 inch in twelve locations. I actual found these bushings already sized at the Tractor Supply Store.
Next I made a backer form patterned off the master form but it was cut 1/8 inch inside the line. I cut 2 nose rib routing forms from 3/4 inch MDF pattered from the master form adding the 9/16 inch flange. For the top form I cut the back line 1/4 inch short of the spar. I cut two 1/8 x 3/4 inch aluminum bar for spacers. These would allow the nose ribs to be routed the proper size.
There are 3 full sized nose ribs per side, 2 ribs per side are 1/8 inch shorter for spar cap strip allowance and the rest (18) are 1/4 inch shorter for double cap strips. The bottom routing form I cut to full size and cut off 1/8 inch at a time as necessary. I started with the full size ribs (6 total, plus 2 spares) then I remove one aluminum spacer off the top form and cut 1/8 inch off the bottom form on the spar side. Then cut 4 ribs and remove the last spacer, cut another 1/8 inch off the bottom form and cut the remaining nose ribs. I counter bored the bottom of the bottom form so the jig would lay flat on the router table.
There are a total of 46 nose ribs (23 each side) needed for the wings.
