Arlin, I brought a recent subject similar to your question to the top as i think it will answer some of your questions. The two ribs I bought recently from Muzzleloader Builder's Supply are milled out and are as close to historically correct as is available commercially, AFAIK. They also have concave milled sides as you can see in the pictures of the thimble tutorial late in the thread. When I was at that stage in the current build on the bench, I studied dozens of images in Jim Gordon's wonderful book, or original Hawken half stocked rifles, to see how the ribs were finished. Almost all had the sides filed flat, with only a couple having concave sides, and even then, they were very shallow. The thimbles were inlet into the rib as I have demonstrated in the thread I referred to. I made no attempt to taper the ribs to match the bottom flat of the barrel. Being milled out hollow, they simply connect with the bottom and side angle flats of the barrel, and are quite secure. Throughout all of the processes of building this rifle including drilling the rod hole through the barrel thimbles, and clamping the barrel in the vise, the rib has not become loose nor has moved at all. The rivets are definitely working as they should.