Entry: Sat May 09 2020

Spent about 30 min this morning laying out and then cutting out replacement blanks for the flap ribs injured by the router guide bit explosions yesterday.

This afternoon got 4.5 hours in the garage accomplished the following:

• Made new flap rib working forms
• Finished trimming remaining flap blanks
• Finished trimming all back rib blanks
• Processed half the noes rib blanks.

The process i'm using to make the rib blanks goes as follows. For each new part I start on, first I do some prep to the jigs.

• Take the master template for the part to the drill press and drill out the jig holes to 1/4"
• Install metal bushing in the jig holes to prevent opening the jig holes from repeated drilling
• Examine the two working jigs and decide which will be used in the top of the sandwich and will be followed by the router bit. Set it aside
• Take the bottom working jig to the drill press and with a 1/2" forstner bit relieve the bottom of the jib holes so the fasteners do not protrude from the stackup.

Once the jigs are ready the following process is followed in batches of 5-10 blanks until all the part blanks are finished. Note the following process is also documented in the photos.

1. Stack the rough blanks in a pile being sure to align them so the part will line up on all blanks.
2. Clamp the master jig on top of the parts and drill the jig locations
3. Deburr all the jig holes and stack them together on the lower working Jig. Once all the parts are stacked add the top working jig to the stack and fasten together
4. Take to the drill press and drill a hole in each lightening hole to router bit access
5. Take stack to the bandsaw and remove excess material.
6. Use a flush trim router to cut the rough templates to match the jig.
7. Admire your work

Hope to have all the blanks roughed out before next weekend. From there the next step will be deburring all the edges.