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Anybody have a good technique? Too late for me as I just spent 3 hours doing it with sandpaper. I am guessing somebody out there in Sonexland was more clever.

One advantage of scratch built ribs - you can edge finish before bending, flanging, or fluting.

A lot of RV guys will use small diameter Scotch Brite wheels mounted on cordless drills to make things go quick. I did the same thing as you though; by hand and done quickly (a few hours). Honestly, I thought mine were so good I didn't put much emphasis on them since I had almost no burrs or other issues. I have a feeling that prepping those ribs may be a situation where people like to make a mountain out of an ant hill; Sonex does a great job in prepping those parts so very little prep is needed to have them ready to install.

Just my two cents of course...

I always thought sanding aluminum was prohibited because the sandpaper leaves residue in the aluminum that causes corrosion. Rather than sandpaper I used scotch brite pads, scotch brite wheels, and files of many shapes and grades. When absolutely necessary used Emory cloth in limited areas.

Jake

Sanding prohibited??
Only with the wrong type of sandpaper, I used aluminum oxide papers. Its the carbon based sandpaper i.e. typical automotive stuff that causes the corrosion problems.
Scotchbrite for the final polishing.
To make scotchbriting a bit easier on stuff a scotchbrite wheel has no hope of finishing use this tip.
Cut out a bunch of maroon scotchbrite circles, about 2-2.5" in diameter, bolt them together, then chuck the assembly into a cordless drill and use that.
Works well. When they get tatty, just cut out some more circles and off you go again.

Bryan,
On the factory ribs in my kit, the lightening holes had a small "nub" where the hole started or stopped, I guess, from the laser or whatever process was used to cut the hole. I just took the time to sand it off and smooth the edges of each hole, by hand. That's probably why I'll have 2000 hours in the project when finished.

Did anyone sand / scothbrite the rib flange edges, or, is it really necessary? Mine are really nice as is, just the small visible laser cutting edge with no nubs, nicks etc. that has been making me wonder if I am making a big deal out of nothing like Mike suggests!

I cleaned mine up on the big scotch brite wheel. The flutes really tear up the wheel.

I did that with the right wing ribs, still finishing up the left rib flanges before riveting. Slowly getting there for round two!