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making nose ribs

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Well-Known Member
Sep 15, 2006
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I had a request for more pics and further explanation of how we made our nose ribs. Hopefully the following will fill in the blanks.


We made our jigs out of 3/4" mdf which is very easy to work with. The above jigs were made to cut out the inside of the nose ribs with a router. At this point the 1/4" birch is still cut in rectangles to fit between the stops on the jigs.


Then the outside shape was rough cut with a scroll saw. A bandsaw would have worked just as well.


The outside edge was trimmed with a laminate trimmer and bottom bearing flush bit.


Some of our nose ribs were a D-shape and most were open ended like the letter C. For the c-shaped ribs, we put a thin stop at the end of the jig. For the D-shape we made a plug that fit in the hole and attached that to the jig. A clamp was used when necessary to hold the ply to the jig.


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