A better shot showing the two forming holes underneath the clamp that I used to alig the two rib sections. Alslo shows the finished front rib after the nibbling and edge smoothing was completed.
Also don't forget to radius the inside corners where the flange is trimmed or nibbled away. Another thing to notice from this pic is the reference line drawn with a sharpie next to the area that has been trimmed away. Always perform major trimming or cutting so that you are not quite to the final trim line. Then perform final sanding, trimming, or grinding up to the established trim line. It's always easier to trim a little more metal away than it is to replace it after it's gone! Many builders have had to order new parts here, either due to improper trimming, or because they mess up the edge distance when trimming the flange or marking and drilling the holes. Thanks to Ron Duren's posts about these problems in his site, I was able to avoid this problem, and my finished parts all came out fine.
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