Remanufacture of wing rib 4 rear spar channel attachment bracket

The supplied rear rib 4 rear attachment brackets (both left an right) appeared ok except for a gap as large as 1mm between the rear flange and the rear spar channel. A complete fix could be achieved with a shim (or perhaps some forcing/reforming) but I decided to re-manufacture them.

I used 0.8mm 6061-T6, folding across the grain, with a bend radius at least as large as the original part and >=2.5x thickness. I created a jig to achieve a bend angle differing slightly from the 90 degrees (about 2.6 degrees) to match the angle of the rear spar channel relative to the ribs. I match-reamed holes after ensuring a prefect fit, and used a nibbler and file to create the notch for the flap rod.