All of the ribs have been formed and the lightening holes have been flanged. I used the "modified Bob-stick" with a taper on the nose. This worked much better in these smaller diameter lightening holes.
Here are the first two aileron TE ribs. Although the picture does not reveal it, I did not need to apply too many flutes to achieve the necessary contour.
Here is a view of the form blocks used for both the aileron and flap ribs. The first set was made of MDF board but I found that MDF did not hold up very well when making these ribs, particularly at the very aft tip of the rib. I finally made the form blocks from oak which worked much better.
The aileron trailing edge ribs and the flap trailing edge ribs are almost identical except in length. In hindsight it would have been faster if I had only made one set of form blocks for both ribs.
I have located and cutout the 1" diameter holes for the counterweight installation. Per correspondence with Mr. Bob Barrows, I will use a 1" diameter. solid aluminum bar as my counterweight.
These are the aileron nose ribs, awaiting the counterweight hole and primer.
Pictured are the layout templates, the form blocks and two of the aileron nose ribs. After cutting out the rib blank, the relief holes for the notches were drilled and then the flanges were formed on the form blocks. I then did a little filing, sanding, and deburring to clean all edges and holes.
When it came to the aileron nose ribs, I had heard that some builders who had already completed their projects were noticing a little buffet on their aircraft when making hard turns so Bob Barrows authorized a rounded nose rather than the sharp contour depicted in the drawing. Correspondence with Bob confirmed this information with the additional instructions to use a solid 1" aluminum bar as the counter weight in lieu of the lead pipe filled with shot.