I started with making the rib jig

  4/19/05    3 Hours    4/20/05    3 Hours

I cut  all the 1/4 X 1/4 spruce for the first rib and fit them in the jig. Then I removed the rib caps and cut new ones to the length I wanted. Now I fit them in the jig and found the 1/4 X 1/4 is off.
I would have to check each cap strip to make sure the inside is the same. Then I cut out ribs for 12 ribs.

  4/21/05      2 Hours

Using the table saw I started cutting the  gussets 172

  4/22/05    3 Hours      4/23/05    3 Hours

Not all the gussets but 520 of them.

  4/24/05           2 Hours 

Fit, glue and staple one side of the rib with gussets

4/25/05       45Min 

Remove rib and put the gussets on the other side.

4/25/05      2 Hours 

Put rib pieces in jig, fit, glue and staple gussets

4/25/05      35 Min 

  Remove  all staples and sand the first rib. One done 43 to go.