Dec 03, 2022     Right flap twist - (2.5 hours)       Category: 22: Flap

When I got the right flap and right aileron installed and rigged, I noticed the flap doesn't align well with the aileron. It is only about 3/32” out of alignment vertically and if that was the only issue I'd probably let it go. Based on what I've read on VAF this is a common issues and in other models 3/32” would be pretty good. The problem in the -10 (and -14) is the pivot point of the flaps means that a 3/32” vertical offset is also about a 1/4” horizontal offset. My conclusion is that the flap is slightly twisted. I am going to drill out the trailing edge rivets and try to untwist it a bit. I hope I don't regret this.

12/6: have about half the trailing edge rivets drilled out. Popped the heads off in the normal manner, but can't really grab the recessed double flush shop heads with side cutters like normal. Opted to just carefully drill a 3/32” hole down the exposed center of the rivet. Most popped right out. No damage to the holes. Still holding a cleco tightly.

12/10: once I had the trailing edge unzipped, I tried to twist it. It doesn't budge. I was afraid I'd damage it if I out too much force in. Certainly doesn't move easily. I thought I had improved it slightly and went ahead and re-riveted it back together. Remounted to the wing and it honestly looks exactly the same as it did.

It's really fine and I'm sure will fly fine. Just annoying. I priced out new flap parts from Van's - about $500. Could throw it into my fuselage crate. I'll think about it.

  Oct 09, 2022     Right flap work - (10.5 hours)       Category: 22: Flap

Deburred the remaining skins and spar for the right flap the. Prepped and primed.

10/10: started assembly of the flap bracket assemblies.

10/11: took advantage of my nephew in town and got a lot of work done this evening. Everything dimpled and started riveting the skeleton together.

10/13: finished the skeleton and got the leading edges and top skin cleco'd and set in the cradles.

10/15; got the top and bottom skins riveted and trailing edge taped and cleco'd to the board.

10/17: got it all back-riveted and finished of. Missing two pull rivets.

10/21: got two rivets from another builder. Right flap is done.

  Sep 24, 2022     22-8: Left flap finish up - (1.8 hours)       Category: 22: Flap

Finally got the shop cleared enough to get back on the left flap. Got the trailing edge double flushes done this evening. Came out really straight. Looks good.

9/25: pressed the bushings into the brackets. Got the initial set with a vice clamp and a block of wood, then fine tuned it with a socket and clamp. Later realized this was probably a mistake as the bottom skins will be very tight fitting over them. Hopefully not too much trouble. My fault for going out of order.

  Sep 13, 2022     22-6 thru 22-8: Back on the flaps - (6.0 hours)       Category: 22: Flap

Stalled out on flap construction a bit as I took care of some misc items. The flap skeleton is just too big for the bench. Got back after it now that the right tank is pretty much done.

Deburred, prepped and primed the right flap parts. Also did the countersinking of the brackets for the double flush rivets.

Then got back to assembly of the left flap skeleton. Was able to squeeze most but there are several awkward rivets that have to be bucked with the double offset. Got the leading edge skin cleco'd on and back in the cradles, then cleco'd the top skin in place.

9/15: got all of the top skin rivets done with combination of gun, back-rivet and squeezer. Flipped it around and got the bottom skin cleco'd in place, then went ahead and set half the bottom skin to spar rivets. I was anxious about that, but picked up a tip somewhere to put tape over the trailing edge dimples to keep them from tearing up my knuckles. What a difference that made. It was actually a breeze. Very happy with the quality; I've come along way since the practice kits.

9/16: got the bottom spar rivets finished and set the pull rivets for the leading edge except the ones adjacent to the brackets. I need at least a 6” drill bit to reach those. After my success with the double sided tape on the ailerons I proceeded with that method for the flaps. Got everything cleco'd down to the door with a little overhanging each end. Looks straight though. Will let it cure a few days.

9/21: got my long drill bit and finished the blind rivets in the leading edge.

  Sep 02, 2022     22-6: Left flap assembly - (1.8 hours)       Category: 22: Flap

Riveted the doublers and flap brackets to the front ribs. Did the double flush rivets on the brackets with the squeezer. Cleco'd together the skeleton. Squeezed the rivets for the leading edge ribs that I could. Need to use the gun for a few on the end ribs.

  Aug 27, 2022     22-5: Left flap deburr, prep, prime and dimple. - (7.0 hours)       Category: 22: Flap

Got all of the flap parts deburred this morning and then cleaned the shop.

8/28: preppped and primed all of the flap pieces in two batches. What a difference a new gun makes. I guess I'll try to do a better job of keeping this one clean.

Got the DRDT2 out and dimpled the skins and leading edges. Dimpled the remaining ribs and spar with the squeezer. Not much for photos today, just a big pile of parts. Ready to start assembly though.

9/1: using masking tape prior to etching is a mistake. Acid gets under the tape and stays. When I pulled the tape, there was a lot of corrosion on the flap brackets. Had to remove it all and went ahead and primed them.

  Aug 22, 2022     22-2 - 22-4: starting on flaps - (4.0 hours)       Category: 22: Flap

Nothing else to work on so starting on flaps. Got some of the initial fit up and fabrication done. Opted to drill the lightening holes in the spacers. Doesn't save much weight by looks cool.

Removed the tab from the main ribs. Just used snips and then a needle file to smooth it out. And little scotchbrite to finish it off. Tedious but easy.

Still a ton of deburring to do. I'll do it all at the end before priming.

8/23: started initial assembly of the left flap just to see how big it really is going to be. It's pretty big. Got everything cleco'd together and marked the trailing edges to trim. Trimmed on the bandsaw and reinstalled.

8/25: had to uncleco the trailing edge so I could cleco it it to the door as I drill the trailing edge. Got it set on the door with just a little overhang on each end. Left clecos in the overhangs for wedge alignment. Then one at a time, started drilling every other hole while inserting clecos through the wedge and into the door. Then went through and picked up all the holes I skipped. The. Unclecod everything a again and shifted the flap over to get the ends that were previously overhanging. Got both ends and then removed all the clecos again and put it in the cradles. Slow going but I think it worked and should be straight. Last step on the page was to match drill the flap brackets with the hardware installed for alignment.

Ready to disassemble, deburr and prime.

8/26: got everything taken apart and realized that I never match drilled the holes in the leading edge ribs. Scoured through the instructions and couldn't find where it says to do it, but I figure now is the last good opportunity to do it. So cleco'd the leading edge back together with the spar and ribs.