SONERAI 1 C-GLRL: THE RIBS

Building the wing, I need to make the difference parts. The Spars come from SoneraiWorks and are already bent. I just needed to cut them to 88-1/8. The other parts are the ribs, he nose and main ribs. To do this, I need to make the jigs, cut the ribs and make the flange (for the first part of the process).

I as I told previously, I am not equipped to make it and I prefer invest in the precision instead of tools. So, My friend Pierre made a 2 pairs of jig. One pair used to make the flanges and the other pair to make lightning holes and the reinforcements.

THE JIGS

These jigs have been made with the CNC. Following the plan, the jigs are in the dimensions of the ribs. The material is MDF 1/2. Strong enough to form the ribs, for the nose rib, we did two 1/4in holes that will be used with two pins as guide when I install the rib and squid it to make the flanges.

For the main rib jig, we did three 1/4 holes to make sure the rib is kept in place during the process and will not move when I make the flanges with the hammer.

Above are the jigs for the nose ribs. Made with MDF 1/2in. The left pair are for the flanges and the right pair are for the lightning holes and the reinforcement.

Here are the main ribs jig.

THE RIBS

The ribs are made with the CNC. Pierre drew the ribs on SolidWorks then convert the data to a software to be used by the CNC. This provide some advantages. I ordered four 4x12ft of 0.025" 2024-T3. Because I need 100in of this material to make the skin of the wing, I use the extra 44 inches to cut the ribs in it. So I saved by buying a larger sheet of 2024-T3 and I use the maximum of the material. The software allow Pierre to optimize the position of the ribs on the 2024-T3 sheet and get less scrape.

We calculated an estimate time of 80 hours if I did all of that manually. With the CNC, I saved almost 65 hours. To make all the jigs and ribs were done in 4 hours.

CNC cutting on the ribs.

After 2.5 hours, the ribs are done. Pierre showed me how to make the flanges and I came back home. It did not take a long time before I spend the evening in my hangar making the flanges!!! It so exciting to work on the first parts of the project. Now it become reality.

I've separated the ribs in two set. The left and right. The airplane need eight nose and main ribs each sides. We made two extra ribs if bad things happen!

Eight ribs will be bent left and the other eight ribs have been bent right. To make the flanges, I use a 2.5lbs hammer with sand in it. With that, the hammer does not rebound when forming the flanges. But before, I spend some time deburring all the ribs.