I called VANs and talks to Scott. Poor Scott, he is stuck at the factory and not at OSH. Scott's misfortune is my benefit.
He looked at the pictures and listened to my description. Scott called me back and said he cannot see anything else incorrect and it may be a bad set of parts (E-509 Rib). He will be sending a new set this week. Thanks Scott!
While driving to my bi-weekly basketball fix, I thought about the problem. In that 15 minute drive I figured it out. I do think it is a bad part. When I got back home from playing basketball last night, I took another look at the situation. It appears the bend in the flange that mates to the spar is bent too far toward the web portion of the rib. This would have the affect of shortening the rib and preventing it from mating to the spar AND also place the E-509 flange holes too far inboard of the spar holes.
I measured the gap between the spar web and the rib flange and it was about .080-.090. I then measured the flange height of the other flanges on the E-509 rib and compared it to the height of the flange on the E-509 rib not mating properly. I would "assume" the flange heights would all be designed to be the same, but the mating flange height was about .090 higher. Eureka, this s probably a bad part.
New parts are on the way

__________________
Michael
Builders Blog
http://elstien.us/wordpress/
RV-10 Builder
Tail Kit delivered 6-2013
Finished QB wings on September 2018
Moved to Port Orange Florida November 2018
Tailcone mounted to Fuselage on 3-1-2020
Finished Fuselage April / May 2020
Working working working on Doors
Engine Ordered (BPA/Fly-EFII 8/1/2020
Dues Paid through 2020