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Each wing rib gets a reenforcing gusset in the top and bottom corners, right where the rib is attached to the spar. There are 4 different types (top and bottom, left and right), for a total of 32 gussets. I made cardboard templates to simplify this task. The plans have you make a bunch of oversized blanks, then trim each one down to final profile. This wastes a lot of material. You can see the excess next to the template.
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I used my templates to make the gusset layout more compact and effecient. A 3/8" drill bit was used to remove the material fromthe tight corners prior to trimming.
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Cutting out the gusset blanks.
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The gussets were stacked and clamped together, making drilling the pilot holes easier.
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Stack of completed aft wing rib gussets.
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The flanges were bent using a hand seamer. This worked well.
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Another shot of the bent flanges on the gusset.
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Lastly, any minor deformation or warping in the gusset was removed with a plastic tiped hammer over the bucking bar.
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This is how the ribs come from Sonex.
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They are pre-formed, with flanges and flutes placed accurately according to the plans. I got a chance to make ribs at the workshop, and they are really not that hard to make. They do take a little time, but it is not a task that would be all that bad for a scratch builder.
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The ribs near the wing root have the spar cap flanges to contend with. They need to be trimmed back to clear the caps.
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I transferred the dimensions from the plans, then used a combination of the Wiss snips and my medium rat tail file to hog out the remaining material.
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The #1 rib on the right win is a little different due to the design of the rear spar. To compensate, 1/4" is trimmed off and a new end flange is riveted on.
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After the ribs are primed, the gussets are drilled and clecoed to the ribs.
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Detail shot of the gusset.
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Gussets are riveted in place and ribs are complete.
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