May 13, 2002

Today I began the long process of preparing the ribs. First, I deburred the lightening holes. I went back and forth between the die grinder and the Dremel tool. Both had ScotchBrite sanding wheels on them. Here's the large pile of main ribs and a small pile of some of the leading edge ribs. It took about 45 minutes to debur all the lightening holes in all of the ribs.

Next, I deburred the flanges of the leading edge ribs. I did this using the ScotchBrite wheel on the bench grinder. This took at least half an hour, despite the simple approach.

Tonight I got organized. I identified all of the leading edge ribs and their respective positions, and I labelled each rib for easy reference. I separated the tank ribs from the leading edge ribs, and left from right.

Next, I went through the process of making sure the flanges are at a 90-degree angle to the web. Very repetitive. After about an hour of doing that, I'm almost done with the process for the leading edge ribs. I've got about 8 more leading edge ribs to go (tomorrow).

I went ahead and fluted one tank rib just for the heck of it. In this picture, it's kind of tough to see, but the rib in the foreground has been fluted and it lays perfectly flat on the bench. The rib in the background is all twisted and contorted...this is how the ribs come from Van's. Fluting effectively "shortens" the flange and alleviates the naturally bent tendency, which is a result of stamping the ribs.

Tomorrow I hope to finish up the flanges and flutes on the leading edge and tank ribs, and hopefully I'll make a dent in the pile of main ribs.

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Dan Checkoway ()