nose rib piece is notably flexible due to the "flat" connection between
the formed piece and L-Channels. The required forces to wrap
the nose skin will bend the nose rib piece over towards one side.|
To resolve this situation, I designed and built a simple support fixture out of scrap hardware store angle and a miss-drilled spar cap (drilled in a mirror image of what was required).Cost .... $0.00
The spar cap served as a crossbar threaded through the lightening holes in the nose rib pieces. The spar cap had #40 holes drilled at a 1-inch hole spacing. That spacing was perfect for attaching the vertical fixture pieces to the crossbar. Since the ribs are spaced at 16-inch spacing (with the exception of the two end ribs).
The total parts were 7 vertical angles (15.25 inches in length with three holes drilled) and one crossbar (8' feet long, holes spaced to match rib spacing). Also, two #40 holes were drilled in each nose rib piece (near the tip and near the flange). You could also drill a hole in the bottom for attachment to the rib section laying on the spar web.
A few Cleco sheet holders and the whole setup becomes very rigid... and SQUARE. Yet, there still is enough flexibility at the edge of the rib to postion the rib as needed to align with the holes in the skin.
Rib piece is easily bent to either side by down forces when installing the nose skin.
Crossbar and vertical support angle.
Look behind the angle to see the two extra #40 holes drilled
in the rib nose piece.
The two vertical holes are cleco'ed to the rib.
The third hole is cleco'ed to the crossbar.
View of finished nose rib support fixture.
Only a few tools and a couple of hours required.
Testing for nose rib evenness by sliding 8' angle up-and-down the seven ribs.
Note: six ribs were "perfect" the end rib was off slightly due to a slight twist in the spar.
Better view of the interconnections.
Three Clecos per rib required.