A Few of the Templates. A Portion of the Full Size Rib on the plans was scanned. Then the Gusset was cut from the scan, glued to Masonite with spray adhesive and sanded to size. The resultant template was then checked against the Full size rib on the plans
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The Rib Jig. The Full size Rib Drawing was taken to a Print shop where it was duplicated 1:1. After verifying that the copy dimensions were correct it was then applied to Medium Density ChipBoard with Spray Adhesive and sealed with polyurethane. If I had it to do over again I would have cut the ChipBoard with a 1/4 inch margin around the rib. Then just clamp the gussets without nailing.
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An Aileron Bay Rib after Glue Up. I started with Aero-Lite Glue per Ron Mason's advice but switched to Weldwood Resorcinol. Weldwood was locally available and gave me visual assurance that I had glued the joint. As you can see a lot of spring clamps were used. The local home store has them for $1/each.
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