Very impressive. Did you hammer the old block into the form or use a c-clamp? It would take me weeks to do that whole process to find material like the block and form and through to end. We don't seem have that kind of heavy steel laying around. Then fashion it into the former and on into the finished ribs.

Did you put the extra stock over the form and clamp it(and how tight?) before you formed it? Or was that after you formed? I imagine you would need something clamped over the to be formed metal to keep it from buckling and to make it stretch into the form? Did you use a shot bag to do your final smoothing or just metal or wood dolly?

Just as impressive is the trimming to fit of everything. Lots and lots of time and work.