Making patterns for wing rib gussets

The gussets on a Baby Lakes biplane are unusual in that they are round instead of the rectangular type that's often times seen on other airplanes.

What I did to make this go a little quicker is I made patterns from some Aluminum scrap I had. At this point the rib jig is built and the nose rib assembly and all the pieces are installed in the jig. I fit the different pieces required on the jig until it was perfect. Then I took the aluminum and sanded it on the disc sander and buffed them smooth on the sanding sponge. Worked out really well.