Here is a view of the nose ribs with the stiffeners installed.
I started making the stiffeners for nose and center ribs. For the most part each stiffener is unique to its location so I did not spend too much time trying to make tooling for these parts.
I trimmed each one to length, then located and drilled the fastener holes. After deburring
This is a view of the nose ribs after being formed. All that is left at this point is to install the stiffeners and apply primer.
This is a view of a nose rib after flanging the lightning holes. After flanging the lightning holes the ribs were bowed somewhat. I rubbed the flanging tool around the flanged holes to stretch the metal somewhat. It did not take too much effort before the ribs were laying flat again.
This is a view of the nose ribs after they have been formed and the lightning holes cut out but not flanged. Due to the curvature of the ribs, I placed a flute between each projected fastener hole on both the upper and lower flanges.
This picture was taken after all the ribs had been formed. I have one of the extra ribs blanks clamped up in the form block prior to bending the flange. I had tried to make a tool for flanging the lighting holes using the original form blocks, hence the hole in this block.
This rib has been cut out and deburred and is now ready to be formed. Several builders have been using routers to cut out the rib blanks; I used a combination of hand and electric shears with a final pass on a buffing wheel mounted in my grinder to clean up the edges.
In hindsight, I'd suggest the use of the router technique.
This is one of the form blocks used for the nose ribs. Note the steel inserts for clamping the form blocks together prior to forming the ribs. Also visible is the notch filed into the form block to facilitate creating the relief hole at the end of the flanges. I later realized that it is not necessary to install steel inserts in the form blocks as these holes are only used for clamping, not drilling.
Here is the layout board I used to mark the outline of the nose ribs and also to drill the jig holes. In hind sight, I should have used a thicker board or different material as my templates warped over time, something I did not expect here in Arizona.
The 46 wing nose ribs are fabricated from .025" 2024T3 aluminum, with a 90 degree flange on the upper and lower edges and two lightning holes, which are flanged to add stiffness to the rib assembly. To achieve the 90 degree flanges on both edges, it will be necessary to flute these flanges to permit the curved contours needed for these ribs. I made a layout board for the nose ribs which included the upper and lower flanges and then glued some blocks of hardwood with steel inserts for the jig and lightning holes. The purpose of the steel inserts is to prevent hole enlargement with the repeated drilling of each new rib. I then made the form block and backing board for these same ribs.