Nov 26, 2021     Flap Assembly - (3.5 hours)       Category: Flaps

With the temperatures forecast to be chilly (less than 50) I thought it best to double flush rivet both left and right flaps while the the temps were in the 70's. Following the procedure described in Section 5 of the manual, both trailing edges were completed with NO bending of the trailing edge and no adjustments were necessary. A big relief after my rudder experience. I then completed riveting the bottom skins to the ribs. Finally, the bushings were installed in the wing flap hinge brackets. With that complete, the flaps are DONE!!

  Nov 24, 2021     Flap Assembly - (1.0 hour)       Category: Flaps

Now that the temperature has warmed up, I applied the trailing edge 3M tape to left flap wedge and then installed it and clecoed the top and bottom trailing edge. The flap's bottom skin was then clecoed to each rib. With this complete, I stacked some weight on the flap to keep it level with the table as the tape cured - which I'll wait three days before removing it to be sure we get 100% adhesion.

  Nov 22, 2021     Flap Assembly - (5.0 hours)       Category: Flaps

Completed checking the twist of right flap and after some adjusting it's now within .5 degrees of perfect. We then riveted the bottom right skin to the spar. The left and right skins were pop riveted to the nose ribs. The upper and lower trailing edges of both flaps, along with the 'wedges were roughed with scotch bright pads and thoroughly cleaned with Isopropyl alcohol. The 3M tape was applied to both sides of the right flap wedges, clecoed at one end and the paper covering the adhesive was pulled off. All the remaining trailing edge holes were then clecoed, all the bottom ribs were clecoed to the skin and then the flap was weighted down flat. I'll let the flap sit this way for about three days to let the adhesive cure.

  Nov 20, 2021     Flap Assembly - (2.0 hours)       Category: Flaps

Back riveted the two aft most rivets on each rib to the left top skin. Completed checking the twist of left flap and after some minor adjusting "settled" for being within 0.15 degrees of perfect. We then riveted the bottom left skin to the spar. Note: The bottom skin to spar riveting, especially at the rib intersections, is a somewhat difficult task as it takes a person with a small, but strong forearm, using the long elevator bucking bar and then a smaller bucking bar for the final few hits, to reach inside and complete the riveting. It also helps if they know what they're doing:-) A rolled up towel helps spread the skins to enable the person to reach safely between the skins. Thank you to Dean for the perfect rivet bucking.

  Nov 19, 2021     Flap Assembly - (5.0 hours)       Category: Flaps

Completed riveting the top left and right skins to the spar. Riveted the ribs to the skins on the right flap and all but the two aft most rivets on each rib to the left top skin.

  Nov 17, 2021     Flap Assembly - (1.0 hour)       Category: Flaps

Clecoed the right flap leading edge to the substructure. Once it was attached, I clecoed the top skin to the leading edge and substructure. At this point the left and right flaps are at the same point of completion and ready for riveting.

  Nov 16, 2021     Flap Assembly - (3.0 hours)       Category: Flaps

I continued assembling the right flap by riveting the plate nut in place then riveting all the doublers onto the nose ribs and flap hinge brackets. Next I assembled the flap hinge brackets with the future attach hardware before double flush riveting the hinge brackets. Next I assembled all the parts to the flap spar and riveted all parts in place. The right flap is now almost to the same point of completion as the left flap.

  Nov 14, 2021     Flap Part Fabrication - (2.5 hours)       Category: Flaps

Making progress on the right flap. I countersunk both the inboard and outboard hinge brackets. The spar was deburred and all #40 holes were dimpled. I removed the blue vinyl on the leading edge skin, deburred the previously drilled nose rib holes and all edges. Then I dimpled all the holes.

  Nov 12, 2021     Flap Part Fabrication - (1.5 hours)       Category: Flaps

Disassembled the right flap, but first labeled everything for reassembly. All the skin ribs and nose ribs were final drilled and dimpled. BTW, I can't say enough good things about the Cleaveland Tools rivet squeezer. It effortlessly dimples and rivets everything in my kit. One of the best tools I own and no, I don't work for them or own stock in the Company. It's an excellent tool and I thought I would mention it to all builders and future builders.

  Nov 10, 2021     Flap Assembly - (1.0 hour)       Category: Flaps

Completed riveting of the left ribs to the flap spar. Installed the left leading edge over the nose ribs and clecoed it in place. With the assembly in place on the flap stand, I inserted the left upper skin between the leading edge and spar. Everything is now clecoed in place and ready for riveting. Note: I plan to 'lubricate' the blind fasteners before riveting them in place, but that's for another day.

  Nov 09, 2021     Flap Assembly - (5.0 hours)       Category: Flaps

The 2 left flap hinge brackets were double flush riveted together while the connection hardware was temporarily installed. Once riveted, the connection hardware was removed and stowed until a later time. The left flap ribs, nose ribs and the flap hinge brackets were clecoed to the flap spar. This sounds so simple but trust me, to do it right it takes 3 or for hands to get things in alignment before you squeeze the rivets. Even then, there is a possibility a rivet or two will have to be drilled out and redone. At this point, all but one rib remains to be installed and one questionable rivet removed and replaced. Oh well. Good practice for the right flap.

  Nov 06, 2021     Flap Part Fabrication - (1.5 hours)       Category: Flaps

Today I countersunk all four of the left and right trailing edge pieces for the flaps. Much time was taken to set the drill press up for the proper angles then it was just countersink and check recheck and repeat a hundred times or so. They're done and should fit nicely.

  Nov 02, 2021     Flap Assembly - (2.5 hours)       Category: Flaps

The left side top and bottom skins were deburred and dimpled, The left inboard ribs/rib plates were riveted together, as was the nut plate for the flap control rod.

  Oct 31, 2021     Flap Assembly - (1.0 hour)       Category: Flaps

Dimpled the left flap leading edge. Yep, it's a busy Sunday and that's about it.

  Oct 30, 2021     Flap Part Fabrication - (2.0 hours)       Category: Flaps

Countersunk the #40 holes in the left flap hinges as called out in the plans. Deburred all the recently drilled holes and the dimpled all the left ribs and the left flap spar.

  Oct 29, 2021     Flap Assembly - (2.5 hours)       Category: Flaps

The flap trailing edge AEX's need to be drilled, but they must be perpendicular to the AEX centerline and not the flap skin. So I placed some pieces of wood under the flap skin then used a level and triangle to ensure the AEX was parallel to the table then drilled the trailing edge on the left and right flaps. Next I assembled the flap hinge bracket hardware onto the flap hinges then drilled the #40 holes on all four hinge assemblies. Once that was done both flaps were marked to ensure reassembly in the proper locations. So far I decided to move forward on the left flap first. Thus, the left flap was then disassembled in preparation for the next steps.

  Oct 27, 2021     Flap Assembly - (1.5 hours)       Category: Flaps

Assembled the right flap and match drilled the #40 holes in the leading edge ribs. The learning curve kicked in and this one went way faster and easier the left flap. The first picture shows the alignment of the outboard rib assembly with the four holes needing to be drilled. The second shows the 2 new holes drilled and clecoed to align the rib for the next pair to be drilled. Repeat for all the ribs and you're done.

  Oct 26, 2021     Flap Assembly - (2.0 hours)       Category: Flaps

Edge finished both leading edges. Assembled the left flap skins and substructure. Caution when doing this as the leading edge is a tough fit and must be carefully "encouraged". Helpful hint? Don't cleco the ribs to the bottom skin until the leading edge is clecoed. Finally, the two holes on each of the ribs were match drilled to #40.

  Oct 24, 2021     Flap Assembly - (4.0 hours)       Category: Flaps

I removed the small tab on all FL-1005-L and FL-1005-R Main Ribs and filed them smooth. All #40 and #30 holes were final drilled. Finally, all the parts were deburred - holes and edges. The spar attach flange on the inboard rib of the left and right end were adjusted and marked as modified. All the puckers were adjusted out. Finally, all the ribs, hinge assemblies, etc were clecoed to the flap spars. The flap substructures were checked, then double checked to ensure everything is in the proper orientation. It'll be checked again prior to riveting.

  Oct 23, 2021     Flap Part Fabrication - (1.0 hour)       Category: Flaps

Final drilled all #30 holes in the left and right hinge pair subassemblies. Deburred all the parts.

  Oct 22, 2021     Flap Part Fabrication - (1.0 hour) Category: Flaps

Final drilled the #30 holes in the L&R Outboard and Inboard rod end ribs and doublers and 2 each of L&R nose ribs. Deburred both L&R flap spars.

  Oct 21, 2021     Flap Part Fabrication - (2.0 hours)       Category: Flaps

The FL-1004-L&R Nose Rib Flanges were buffed and deburred. No fluting was required. The #40 holes were drilled and countersunk and the 1/4 holes were drilled. All parts were deburred. The F-1006 edges were deburred. The Inboard and outboard parts were clecoed from the inside.

  Oct 21, 2021     Flap Part Fabrication - (2.0 hours) Category: Flaps

The FL-1004-L&R Nose Rib Flanges were buffed and deburred. No fluting was required. The #40 holes were drilled and countersunk and the 1/4 holes were drilled. All parts were deburred. The F-1006 edges were deburred. The Inboard and outboard parts were clecoed from the inside.

  Oct 19, 2021     Flap Part Fabrication - (2.0 hours)       Category: Flaps

I made the cradles to support the flaps as they're being built. Later, this cradle will be modified to construct the ones for the ailerons. I adjusted the flange of all the flap hinge brackets, then drilled the #40 holes as described in the plans, but only for the left brackets. All the nose and main ribs had the protective blue vinyl removed and were labeled.