First thing I did was build a tool to straighten the rib flanges to a nice 90 degrees. The plans for these are apparently in the RVator newsletter somewhere, but I got my information from other builder’s sites. The construction is quite simple. A 2x4 with one end under cut by 11 degrees (on the table saw) mounted to a piece of 1x8 with short dry wall screws. A 2x2 with the same 11 degree undercut and narrowed at one end is then mounted to the 2x4 with a hinge. I made all of this out of scrap lumber I had laying around in about 15 minutes. The only delay was locating a hinge. I was certain I had a used one sitting in a coffee can or toolbox somewhere but after 15 minutes of searching I was still empty handed. I ended up de-installing a padlock hasp from one of my outbuildings. I didn’t have the key for the padlock anyway. If you do some searching on Van’s Airforce you will find some nicer designs. This thing works incredibly well and is very easy to use. Like all things with these wing ribs however, it takes a long time to work your way through all of the flanges at an inch or so at a time. Next was fluting. My technique so far: 1) grab a rib and the fluting pliers. 2) sit down and put your feet up. 3) Flute your way around the upper and lower flanges in between the rivet holes. 4) Lay the rib on a nice flat table to see how close it is. Flute more if the rib is still bowed up in the center (shorten the outer flange by fluting), or take some fluting out with the hand seamer if the ends of the rib are proud of the flat surface. Obviously you can’t flute until you know where the holes are for the undrilled end ribs. The fine tuning takes a little while. I’m hoping that after a few more of these it will go quicker. I think I had about six of main ribs complete when I started thinking about my vacation in Idaho for the July 4th week and not making any progress on the project. Flange straightening and fluting could be a nice low tool count activity if I hauled all the unfinished ribs with me to
