Wing Ribs 1

1st step is prepping the ribs.  This takes forever, and you have very little to show for it.  To deburr the lightening holes and edges, I use the 2" scotchbrite wheel mounted in the die grinder (1" wheel for smallest holes).  It makes lots of grooves in the wheel, and I found that it worked best alternating between running the grinder parallel and perpendicular to the edge (perpendicular takes the groove out).  I then used a scotchbrite pad to get in the small corners.

Once everything was deburred, I bent the flanges to ensure they were 90 degrees.  This did not take much work , as they were all veyr close.  Once everything is squared, you then have the flute the ribs so that they lay flat.  Easiest way is to lay them on the table and put the flute at the low spots>  As you can see, many of the ribs were very bent.

Once the ribs are all prepped (days later), you cleco and drill them to the spars:

Disassemble the skeleton, then deburr all the holes.  I tried two different extensions to get to the inside of the flanges.  One was a flexible extension, and the other was a 12" "lock and load".  The 12" worked much better, as it was rigid and spun more true.

Next you have to decide where to run your conduit for the wiring.  I decided to use the regular black conduit Van's sells.  It is very lightweight, and should provide plenty of space.  After researching the list, I decided that the best location was behind and below the 1st lightening hole.  After determining the proper position, I drilled one of the ribs to #40.  I found that you could then clamp the rib to one of the opposite facing ribs to locate and drill the next hole.  I used tooling holes and spacer to align them perfectly...worked very well.  Once they were all #40 drilled, I used a unibit to open them up to 13/16 (conduit is 0.81"). 

Here's a better picture of the conduit location.  The piece is laying on the bench upside-down, so the hole is actually on the bottom.

After prepping all of the ribs for the final time, they all get primed.  I used a traditional deburring tool and dremel sand drum to clean up the lightening holes.