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Here is the way I cut all the 016 6061T6 aluminum for the slat ribs for my CH750. I didn't need the cutout blocks at all. The precision of the cnc plasma cuts were dead on. Just deburred a bit and went right on forming the ribs.
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So, If I were to make that brake over again, and money was no issue, I would make the bending beam (the part you pull up on) .750 to 1.00 inches thick. I still may remake my beam one day, but wish I would have over built it from the get. Don't get me wrong, that brake has been priceless, and the KEY tool in making an airplane, it just flex's a little in the middle when you have a heavy long bend like 8ft .040.
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