Making Metal Wing-Ribs

John has been building what he calls his "Floor Sweepings" airplane.
It is an experimental category, home-built aircraft that somewhat resembles a Super-Cub.
He gave this airplane the unique name because it has been built, in large part, using left over bits, pieces and parts from several other aircraft projects he has worked on over the years. Some of the pieces were literally "Swept up" off the floor during clean up after those projects!
In this video he demonstrates how he has chosen to build the metal wing-ribs he will install on the aluminum spars he purchased for the craft.

[@MrPagnu]

Best rib construction video demo I’ve seen in 10 years thank you for sharing

[@JNEAircraft]

Thanks for watching and taking the time to comment!

[@lmfarms4611]

What's going to happen when all of the old ways are gone? Beautiful craftsmanship, thanks so much for sharing.

[@JNEAircraft]

Folks will be looking for the "how to" videos on KZbin to figure out the "old ways" when the "old folks" who used the "old ways" are no longer around! We spoke of this before John's father passed and lamented that we would no longer be able to call him up and say, "I've got an issue I just can't figure out. How would YOU fix [insert the issue]?" Thanks for taking the time to watch the video and for commenting. We hope more folks who know the "old ways" will take the time to capture the techniques on video and share them with the world!

[@joewalker2089]

Enjoyed watching your fabrication wisdom very much and your very able assistant behind the camera provided great input as well 👍👍

[@JNEAircraft]

Thank You so much for taking the time to comment! We appreciate that!

[@javiervidaurre6325]

Thank you Mr Norman. Excellent demonstration and technical explanation. Ingenious techniques. His is a real MAN CAVE. No colored lights or shiny surfaces here. The stereo is the hisses from his double air hose M.O. Gumption in action. I see a brass era Model T, a full dress Harley, 3 other motorbikes, 3 airframes, a steam engine, a big block V-8 engine, 2 vintage radial aircraft engines and tools at every turn. Thanks to the co-host camera lady for her insights.

[@JNEAircraft]

Very kind remarks! Yes, his IS a real Man Cave ... no colored lights for sure, and all the surfaces are usually cluttered with tools, or pieces of whatever he is working on at the moment! LOL. I sometimes cringe when we make these videos because of the clutter ... but I try to focus on the subject of what he is demonstrating in order to capture the technique in such a way that it is easy for others to understand and follow if they are trying to figure out HOW to make a similar part! Thank you for watching and taking the time to post a remark! It is much appreciated!

[@redwolfmotovlogsandstuff7302]

Didnt know it was this easy to form a metal rib, alot of time saved compared to wood construction. I appreciate you documenting this and sharing your knowledge. Youve made what seems to be a pipe dream of mine more acheivable.

[@JNEAircraft]

The tooling takes time, but once you've got it ready to go, it simplifies the process. Glad this little video helps! Thanks for watching and good luck on pursuing your "pipe dream" ... there is a tremendous amount of satisfaction that comes with accomplishing something that others tell you is "impossible"!

[@tomharns1514]

Fantastic John! always fun to watch you "create"

[@JNEAircraft]

Thanks, Tom!

[@tomcoryell]

Thanks for showing the process for hammer forming ribs. I particularly liked that you did some shrinking to take out the curve before pressing it in the die.

[@JNEAircraft]

Thank YOU for taking the time to comment! Glad you liked it.

[@bradmarcum2927]

You are a true craftsman sir.

[@JNEAircraft]

Thank You!

[@MrJdorrington]

Fabulous. Thanks for filming.

[@JNEAircraft]

Thank You for watching!

[@ramjet4025]

Wonderful demonstration of metal working for homebuilt aircraft.

[@JNEAircraft]

Thank You, Ram Jet!

[@MB-zj3er]

Pretty cool. Thanks for the video. 👍

[@JNEAircraft]

Thanks for taking the time to watch!

[@verbonloucks6498]

Very precise, love the ordeal of non high priced tools, and jigs this is what I like in the close knit aviation soc!

[@JNEAircraft]

Thank you for taking the time to comment! We don't like investing in high dollar items that will only be used a few times when we can make what we need out of what we have available. Trying to keep the cost of aviation restoration to a manageable level where we can!

[@TheAamirRauf]

Wow this is amazing! It's wonderful to see him work!

[@JNEAircraft]

Thank You, Aamir!

[@TheAamirRauf]

@@JNEAircraft I'm planning to start a kit built airplane - videos like this are a HUGE MOTIVATION. I plan to make some dummy ribs from sheet metal to get used to working with that type of material and riveting etc. Please keep these videos coming! God bless!

[@user-ul9ts7zw3g]

Great, simple technics thank you.

[@JNEAircraft]

You're welcome! Thanks for commenting!

[@stevecorley6014]

Very good! Think your techniques and "equipment" can be adapted to making some metal ribs for one of my projects. Thanks!

[@JNEAircraft]

That's what it's all about! Sharing techniques to inspire others to be creative so they can do their own projects without having to hire outside help if it's not necessary! Glad you felt inspired after watching this little video clip! Thanks for letting us know!

[@brianskeens647]

A true master craftsman! Nice haircut by the way!

[@JNEAircraft]

Thanks!

[@user-dr6wl1yd8f]

Great work sir ,from pakistan❤❤❤❤❤

[@JNEAircraft]

Thank You so much! We appreciate you taking the time to comment.

[@kitasuhill9667]

Methodical and theraputic ! Oh if only I could be like you John ! Now .... where did I put my Ritalin ?

[@bobguarnieri280]

Very cool video, thank you!

[@4567bs]

Way clever! Enjoyed it!

[@JNEAircraft]

Thanks! Glad you enjoyed it!

[@jimd421]

Thank you so much for taking the time to show us this. Today's Thanksgiving and I gotta give you. Thanks for the time you took in doing it very impressive.

[@JNEAircraft]

Thank you for taking the time to comment! Happy Thanksgiving to you and yours!

[@garthlee8166]

Brilliant many thanks the camera lady adds cool teamwork dynamic to the video, you are an awesome team well done and thanks for sharing that will follow further and check the rest later when I can

[@robertlafnear9115]

For a Few Dollars More (lol) you could do like Mike Patey and CAD draw these with Solid Works... send that to your CNC router and mill these out of solid 6061 Aluminum bar stock and in the time you used to pound out one of these all could have been milled.🤔... no Hammer marks nor Vice marks🤨 OR like I did build a HYDRO press usa rubber sheet and in one pass do it all.🤗 AND building the press was FUN !

[@JNEAircraft]

If you HAVE a CNC router and choose to mill them out of solid 6061 Aluminum bar stock ... OR have the time to build a HYDRO press as you did. When you are working 40+ hrs. for the man PLUS doing this kind of work on the side, you still have to choose what you spend your time on based on how many times you'll be doing what the current project requires.

[@robertlafnear9115]

O.K.

[@Guy_6397]

Folded ribs are actually stronger than milled ribs as the metal fibres haven't been cut on those edges. Although not a fibrous material in the wood sense, metal does still have a grain and is stronger when bent.

[@scottbtraveling1444]

Great video on your rib production. I'm looking forward to viewing any other aviation related content you may have on your channel.

[@JNEAircraft]

Thank You for your comments. We originally started the channel to focus on The Spirit of St. Louis by JNE ... but since John is in the "restoration" business, we thought some people might be interested in some of the processes he incorporates as he builds new parts ... or restores serviceable used parts. Thanks for taking the time to watch!

[@ronwhittaker6317]

love it very useful

[@JNEAircraft]

Glad you found it helpful. Thanks for watching!

[@mecanicodejetski]

Thank's to this video all her experience will be preserved, and will not end in an state sale or trash can when he left her body and fly whith good, thank you for share this, may be he has a serie of how to ?

[@JNEAircraft]

As we can, we have filmed some of the techniques John uses when he is fabricating new parts for old airplanes and we post them here on KZbin. You can see a full list of the videos we have posted by going to the "videos" page on our channel: www.youtube.com/@JNEAircraft/videos

[@mariolarico4413]

THANK YOU VERY MUCH. ! I’M. FROM PERU

[@JNEAircraft]

Thank You for Watching and taking the time to comment! We are happy to know that people in Peru are watching too!

[@dogguyful]

Awesome 👌👌👍👍🙏🙏

[@JNEAircraft]

Thank You!

[@phimultiplypi]

Grizzly tape😂 cracked me up!❤

[@titikindah5504]

You are genius

[@JNEAircraft]

Thank You, titik indah!

[@stevenlarose7325]

Well damn it man After watching the wood rib video and this I think I will go wood.. Was a Cabinetmaker at 1 point in time. Plus I don't have that press

[@JNEAircraft]

Just need to figure out what works best for YOU. Keep in mind, these demonstrations are just what have ended up evolving for JOHN as the "best way" to get the job done depending on which material he's working with. Thanks for taking the time to watch BOTH of the rib making videos!

[@titikindah5504]

Genius tecnic

[@JNEAircraft]

thank you!

[@chrisybradshaw8594]

wow awesome

[@JNEAircraft]

Thank You for watching and taking the time to comment! We appreciate knowing your reactions.

[@noellwilson1273]

Super camera work!

[@JNEAircraft]

Thank You! I sometimes fear I'm moving too fast, but I don't know how else to keep up with John as he is performing each step of the process ... he doesn't know HOW to slow down! LOL

[@noellwilson1273]

I’m mainly impressed with the camera staying still and focused on the job instead of jumping around to the point of making me seasick. The only time I had a “Wait! I want to see more detail.” was at 12:30 and the matched die press. You provide some of those details in answering the question from Russia (?) about a stencil. If you ever run out of subjects, a short video on that press making a complete Cessna rib would be interesting.

[@JNEAircraft]

@@noellwilson1273 Thanks! I understand about the "seasick" issue, so I try real hard to keep it still and NOT move too fast from one position to the next ... but as I'm slowly moving the camera, John is on to the next aspect of whatever he is demonstrating! That's what I mean about keeping up with John! LOL Thanks for the suggestion about making a complete Cessna rib. We will keep that in mind if we get a Cessna project in the shop!

[@dundas9222]

Pretty cool! I enjoy that kind of work. Saw some pretty cool stuff in the shop too, like those radials, and what are you going to put that Big Block in?

[@JNEAircraft]

The big block is going into a roadster (along the lines of a '32 Ford) that John is building from scratch!

[@freitasn1029]

Obrigado pela excelente aula , gratidão senhor João. Wessiley do Brasil

[@JNEAircraft]

You're welcome, Wessiley! Thank YOU for watching and taking the time to comment!

[@ristosalonenrs2000]

Yes it's great to watch a professional man do with competent hands and reason, I value that kind of know-how., I've been thinking about aircraft construction and I've just been thinking about a light build., that way it becomes light and sturdy.. Thank you was a great look, man from Finland. Also, I subscribed to your channel.

[@JNEAircraft]

Thank you for subscribing and Thank you for taking the time to comment on what you have seen! We appreciate the feedback. Hopefully what you have seen here will be helpful as you move forward with your own project!

[@richardm.gramling1772]

Sir, your girl friend camera person did a great job for an accomplished novice following you around your shop.

[@JNEAircraft]

Thank You, Richard!

[@456Broscowagner]

Nice...show ... Muito 😍

[@johnwalker863]

A true crafysman

[@JNEAircraft]

Thank You, John!

[@riccodelestaque7720]

It's very interesting, thank you, I like this work by hand without expensive machines. Otherwise, when you are lucky enough to have a person on camera, this person should learn the minimum to film correctly, the movements of the no one who works with metal, there is no point in following it, and the principle in video is to take fixed views, or at least by moving as little as possible, we can also cut passages during editing, I sometimes wonder if the camera man watches his own images. In addition, they are basic and do not require any expensive equipment, but if you do not observe them they make viewing difficult.

[@JNEAircraft]

Thank You.

[@riccodelestaque7720]

@@JNEAircraft I really appreciated your work, it's a shame that it's not served by an amateur videographer, who thinks that we film as we see, as we look. Let her be inspired by this: www.youtube.com /watch?v=XxdBtYyiViY&ab_channel=AllTimeClassicMovies, the Lumière brothers understood for the world's first film that the camera had to be fixed. This is a real disservice to your work, too bad. I'm watching you from France (today is D Day). 😁

[@TheSlingwing]

Awesome job. What is the thickness of the aluminum used? Thanks

[@JNEAircraft]

The sheet is .025. Thanks for watching!

[@user-rf9on8ex7v]

👍

[@hillbilly4christ638]

I am assuming this is lighter than wood. Is it stronger? Can the wing sustain a higher g force using suitable aluminum verses applicable wood and glue? Maybe it is a stupid question.

[@JNEAircraft]

The only stupid question is the question that doesn't get asked when you really want to know! The weight of the ribs are about equivalent between wood and metal, but there ARE variables depending on the moisture content of the wood. These metal ribs ARE stronger than wood or even regular "stamped" metal ribs. The wing sustaining a higher "G" force has more to do with the rib spacing ... adding more ribs allows for higher "G" force but sturdier spars would be highly recommended in that case.

[@briansilcox5720]

Concrete inner rib dye? I learned basic metal working from a friend at KTIW about 25 yrs ago, all his techniques followed your strategy, simple, available tooling.

[@JNEAircraft]

No need to make things more complicated than they already are! Thanks for taking the time to comment!

[@engineerahmed7248]

Al Castings would be 10 times time effective , strong and neat for ribs

[@JNEAircraft]

If one were planning on mass producing the ribs it probably would be. Since I'm only planning on building this one plane (of this design) it's not worth the time and investment when I have everything I need to do it this way. Thanks for taking the time to comment!

[@user-nq5is4vy8c]

Sir, you have to get a bigger rubber hammer, that hummer is not big enough. 👍😁

[@JNEAircraft]

🤣🤣🤣

[@briankrieg5801]

Are those airplane cylinders and heads on the bike in the cubby?

[@JNEAircraft]

Yes! They are 985 Pratt & Whitney, 218 cubic inch. cylinders. John got that far on the custom motorcycle he built from scratch ... and then took on a 1942 Hawker Hurricane restoration project and all forward progress on the bike came to a screeching halt! LOL. Maybe one of these days when he stops working on airplanes, he'll get back to the bike. In the meantime, she's pretty content right there in the cubby watching all the activity taking place around her!

[@regdor8187]

Left out of your presentation is the design criteria for the forms needed to hammer the aluminum into...Looks like it may take more work to produce the forms than the final rib bending....

[@JNEAircraft]

Definitely time intensive to get the tooling perfected for the job at hand, but once the tooling has been perfected we know we end up with a uniform product that will last for years. We didn't take the time to detail the design criteria in this video because most people don't plan on doing what John has done ... and those who really want to know, reach out and ask for more details. Thanks for taking the time to watch the video and comment on what you have seen!

[@timepass-oc2kj]

Fantastic sir wings Ribs thickness ?

[@JNEAircraft]

.025 of 6061 T-4

[@conradcobb3257]

do you happen to have a stencil available for print? for the form and sheet?

[@JNEAircraft]

No, he doesn't have a stencil available for print. He laid down a piper rib and traced around it on a sheet of aluminum and added some for the amount of flange he wanted. He used an epoxy-steel mold made from 2-pieces of I-Beam to press them.

[@kenan8795]

what type of Aluminium that is and thickness? Tx for video

[@JNEAircraft]

It is 25-thousandths, 6061, T-4 Aluminum. Thanks for watching!

[@ArcticKatieJill]

Good morning first time watcher I am building a part 103 plane looking for aluminum wing ideas instead of wood sticks great refresher course I can’t believe no one commented on your bikes pocketed into the wall a shovel head bottom end with airplane top end and a Cushman and big block Chevy with aluminum heads very cool do you live near Maine?

[@JNEAircraft]

Thanks for taking the time to comment! You are very observant to have picked out the details on the bikes we have in the "shadow boxes" in the wall. We live on the opposite coast ... about as far away from Maine as it gets! LOL We are in Washington state ... about 45 miles south of the Canadian border!

[@user-qt8mk5xk7x]

Очень интересно.сборка крыла полностью есть ?

[@JNEAircraft]

This process is just for the wing ribs themselves. Next they need to be slid onto the wing spars which are then attached to the fuselage.

[@Jesusistheonlyway86]

How did you build the jig?

[@JNEAircraft]

For these ribs I used 2 different jigs. The stiffener bends were made between 2 dies made from 8x8 I-beam with epoxy on each half, making the stiffeners. Then I pulled it out and formed each rib on the outside with a die made from 1 inch aluminum, then once the flange is formed I used 1/2 x 1/2 bar stock shaped like the rib, and clamped it to the flange and rolled the outside flange. you wind up with a very stiff wing rib.

[@Jesusistheonlyway86]

@@JNEAircraft How did you cut the jig?

[@JNEAircraft]

@@Jesusistheonlyway86 I used a band saw and a milling machine.

[@AGGELIAFOROS]

I suppose that v8 at the back will be necessary

[@JNEAircraft]

Of course! It will be necessary for SOMETHING! LOL

[@ARMY_RUGS]

How do i contact you please. great job

[@JNEAircraft]

Due to maintaining an element of privacy in our own lives I will not provide a phone number here in such a public platform. However, you CAN send us a message by clicking on the "Contact Us" button in the lower right corner on any of the pages of our website: www.jneaircraft.com . You may have to chose your 'cookie' preferences before you will see the button. Thank you for understanding.

[@sirbriantherogue6692]

🎶I can’t live 🎵

[@JNEAircraft]

"Rogue Fish Transport" now? LOL

[@sirbriantherogue6692]

@@JNEAircraft hah! I’ll make it. But now that song in the background is in my head again 🙄

[@JNEAircraft]

@@sirbriantherogue6692 LOL

[@johnwalker863]

Craftsman

[@JNEAircraft]

Thank You, John!

[@meherbabagodinhumanform9414]

💘💘💟💟❣❣

[@claytonbuckley8626]

What aluminum is being used here?

[@heathernorman4805]

John used 6061-T4 for these ribs.

[@claytonbuckley8626]

@@heathernorman4805 any idea of the thickness? Cause they look to bend perfectly.

[@JNEAircraft]

@@claytonbuckley8626 He said it was .025 thickness.

[@claytonbuckley8626]

@@JNEAircraft thank you for the information, let him know it’s great work!!

[@GWAYGWAY1]

Turn the radio off ,I want to hear what you say not the local blurb stations.

[@JNEAircraft]

I'll try to remember that the next time I capture his work on video!

[@Love2FlyKAP]

You should be using a "Sheet metal SLAPPER" not a hammer.

[@JNEAircraft]

Thanks for watching the video and sharing your thoughts with us. This video is only to show how JOHN has created the things he has, using the tools available to him in his shop. When you're 'old school', making your dream come true with only the tools you have in your workshop, you use a hammer.

[@andresoteroeirasgranda5870]

I cut a tendon in my hand for not wearing gloves when cutting a sheet metal.

[@JNEAircraft]

Yes, one must always be careful when handling sheet metal! Sorry you were hurt.

[@andresoteroeirasgranda5870]

@@JNEAircraft Thank You. Nice airplane.

[@PDZ1122]

Those rib flanges are full of stress raisers after that brutal treatment with a shrinker and whacking it with a steel hammer. I would never use a shrinker on a structural part. You don't need a magnifying glass to see how it damages the metal. No, it's not going to cause some Cub-clone to come crashing down straight away, but there is a right and a wrong way to make ribs. This is horrible.

[@JNEAircraft]

I have no idea how many years YOU have been building and restoring aircraft to airworthy condition that satisfies the FAA inspectors, but by all means if this method concerns you, do NOT try to replicate what John has created here. You are correct, there certainly are right ways and wrong ways to make ribs and every other part that an airplane requires in order to fly safely. If this method makes you uncomfortable, do NOT utilize it when making your own ribs. If you are EVER in doubt be sure to double check your own preferred method with your local FSDO officials.

[@tinolino58]

He is married -She knows better 😅

[@scoobydog411]

You can get more likes if use 2 mics. Cant hear man talk.

[@JNEAircraft]

So sorry John's voice doesn't carry as well as one might wish. If we ever decide to go into business making videos demonstrating the skills John has acquired over his years of aircraft building and maintenance, we will invest in proper video equipment and "set" the stage to be more professional in what we produce. These videos are simply spur of the moment on my part when I realize he is doing something that others may benefit from seeing, so my phone camera is the best I have available and the mic on the phone is all we've got. Whether folks take the time to watch and give us a "like" or not is immaterial to our intent. Thanks for watching though and for taking the time to share your comment with us!

[@giacomosassi7140]

OFFICINA ANNI 1890! 🤣🤣🤣

[@garthlee8166]

Brilliant many thanks the camera lady adds cool teamwork dynamic to the video, you are an awesome team well done and thanks for sharing that will follow further and check the rest later when I can

[@JNEAircraft]

Thank You! Glad you enjoyed watching!