I started making the form blocks for the stabiliser along with all of the wing form blocks. I used 18mm MDF, rough cutting them with a jigsaw, then sanding the edges down on my disc sander. Although this was a fairly cheap machine it did the job quite well and has been a very handy tool to have in the garage.
I also made up a complete set of cutting blocks for the main wing ribs and nose ribs. These are simply a 20mm larger version of the rib form blocks. The rough cut rib blanks are cramped and sandwiched in between a pair, then a router with a trim cutter is run around to give a nice clean finish.
By matching the tooling holes in the form blocks, the blanks are then be inserted between the formers and bent over with a slightly oversize flange. Then it’s just a matter of bending them over to complete the ribs.
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