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When I made my mdf forms, I used my 032 2024 mylar template. In the photos I started my center rib with a sheet of mdf that had been pre ripped to 32 inches. I then could overlay my template and fix it to the mdf to lay out the flange that will eventually be bent over. There is no need for precision with the flange. There is a need for precession at the spar ends.
I then can group a bunch of 2024 blanks together and route the parallel sides that will exactly line up with the mylar marking for the spar.
Having made my mdf forms in this way, I am reluctant to ever cut the 2024 ribs. As long as I do not touch them they contain the dimensional distance and 90 degree spar relation.
I did play musical chairs with my ribs moving them around to the best average location for each "rib spar location".
The following is speculation:
For the optimum number of 2024 blanks -per sheet- they are laid in different directions in relation to the aluminum sheet grain. Latter when I would bend the flanges, I would get slightly different bending characteristics. Hence not all ribs are bent the same.
The other possibility is that I am not good at using a rubber mallet.
In either case it is nice to be able to move ribs around to match the variation in the spar.
Once the location is chosen for each rib, I can notch or not notch whatever is appropriate for that location.
Also, I did not mind that I get a better rivet to edge distance on the majority of rivet locations.
I then can group a bunch of 2024 blanks together and route the parallel sides that will exactly line up with the mylar marking for the spar.
Having made my mdf forms in this way, I am reluctant to ever cut the 2024 ribs. As long as I do not touch them they contain the dimensional distance and 90 degree spar relation.
I did play musical chairs with my ribs moving them around to the best average location for each "rib spar location".
The following is speculation:
For the optimum number of 2024 blanks -per sheet- they are laid in different directions in relation to the aluminum sheet grain. Latter when I would bend the flanges, I would get slightly different bending characteristics. Hence not all ribs are bent the same.
The other possibility is that I am not good at using a rubber mallet.
In either case it is nice to be able to move ribs around to match the variation in the spar.
Once the location is chosen for each rib, I can notch or not notch whatever is appropriate for that location.
Also, I did not mind that I get a better rivet to edge distance on the majority of rivet locations.
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