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I have reviewed several methods of flanging the lightening holes and felt that there had to be a better way. What I came up with was a rotary flanging tool that I designed. If you decide to use this method you must make sure that all you r rib blanks are exactly the same by using the router method to build them as well as developing a master drill jig to ensure that all holes are the same on every rib. If this method appeals to you then follow along as I build a "Rotary Flanging Tool" The first step is to get your local steel fabricators to bend up a blank of 4" X 12" X 3/16" steel to the following shape. It is basically a 90 degree bend at 2" and a 35 degree bend at 1". The 35 degree bend sets the flange angle of 30 degrees and allows for some spring back. From this basic shape you need to cut two raw finger blanks 3/4" wide.
Each of the raw finger blanks must be drilled and tapped for the roller studs. Drill and tap to 5/16 standard thread.
After drilling and tapping form and finish the fingers on the grinder as shown and set aside for now. Cut two pieces of 1 1/2 square tube into two pieces 2" long and one piece of 1 " square tube 12" long. These will make the sliders and center bar. The sliders are marked dead center on one side and drilled and tapped for 1/4-20 threads. Using a sacrificial bolt attach a 1/4-20 nut to the slider and weld in place. After cooling install the knurled knobs and set aside.
Position the finished finger on the slider as shown and weld in place. After cooling install the Roller on the slider with the shoulder bolt and slide onto the 1" center bar.
Final assembly consists of placing the two sliders on the center bar and installing a 10" piece of 3/8 all thread into the center of the center bar and install the nuts and washers and "T" handle as shown. this completes the construction of the Flanging Tool from the parts illustrated.
To use the tool a formed rib blank is positioned in a flanging jig with the lightening holes 3/8 larger than the rib blank. The flanging tools 3/8 all thread is threaded into the backing plate that the rib flanging jig is attached to. adjust the sliders so that the rollers are just inside the cutout and begin turning as you tighten the center nut. this will pull the tool into the jig and the rollers will set the flange.
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Send mail to lfoor@acsalaska.net with
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