Step 1 router a bunch of rib blanks all at once. Step 2 debur edges. Step 3 Press rib blank and make round flanges. Step 4 Put blank with round flanges in a mdf assembly Step 5 Rubber mallet $7 Step 6 Add scallops while slowly being formed There are many ways of straightening potato chip rib once flanges are hammered. This is my way of doing it: Step 7 Place rib in my flange finish tool Step 8 Press down- Clamp Flange edges with set screws. Step 9 Use wooden dowel to force flutes into scalloped out mdf form Step 10 Still have to over bend flange because of aluminum spring back.