After finishing the gussets, I started to modify the ribs that they are mounted on. The ribs with gussets have to have the top and bottom flanges trimmed back to fit the tapering spar caps at the inboard rib locations. Each one is trimmed to a specific length for its mounting location.
The two pictures below show the cut in process and the second one shows an unmodified rib – the eight outboard ones are unmodified. I made the cuts with hand shears and rounded out the 1/8” radius with a 1/4” round file. Very quick, and easier than drilling a 1/4” hole, cutting to the hole and then filing anyway.
The next four pictures show the ribs cut with the gussets in position, and then the gussets being attached to all eight ribs – four for each wing.
