Nose rib template for the wing rib jig

I started the project by making a nose rib template. The material is phenolic and its very hard, this allows me to have a perfect pattern to use on a table router.

I cut up a sheet of 1/4" aircraft grade plywood into squares. Bolted the pattern up, market it with a knife/pencil, took it apart, rough cut it on a bandsaw, bolted it back together, then routed it out.

 Here is a side view.

A router bit is round and the pattern has a sharp notch in it that needs to be cut out free hand. I simply left the part clamped to the pattern and took a razor knife and cut it out using the pattern as a guide.

This is the starting point of the nose ribs. Each one is perfectly matched to the other because a router follows the pattern.