Feb 25, 2024     Flap wiring - (1.0 hour)       Category: 40: Flap Sys

Just tidied up some of the flap motor wiring. I was planning to install a terminal block behind the flap torque tube cover to transition the wiring from the supplied wire to my wiring. The supplied wire is long enough to run all the way to the sub-panel, although not to the GAD27. I will install a terminal block in the panel or below the torque tube cover.

In the meantime, installed a couple of adel clamps to secure the flap motor wiring within the tunnel and below the torque tube cover.

  Feb 04, 2024     40-5 thru 40-8: Reinstall Flap system - (1.5 hours)       Category: 40: Flap Sys

Now that the bottom rear floors are in I can get back to where I was on the flap system install. Got the torque tubes reinstalled with the appropriate hardware and then mounted the flap motor. Nothing to it.

Need to torque the outboard bolts still.

  Nov 05, 2023     40-4 thru 40-8: Flap work - (4.5 hours)       Category: 40: Flap Sys

Finished cutting the support blocks.

After some trial fitting and anticipating difficulty getting the support blocks over the torque tube powder coasting, I tried putting the torque tubes in the freezer. Was able to fairly easily get the supports over the frozen tubes.

Had my brother in law in town and he helped me get the tubes installed and bolted the blocks in place. Then installed the center flap crank and installed the AN3 bolts. Initially had the clocking of one of the tubes off by 180 degrees and it was enough to make the installation of the bolts very difficult. Thought I could tap it in with a mallet but ended up marring the threads a bit. Will need to order a new one.

Installed the AN4s that secure the external flap horn. Those bolts were tough to get to but managed.

Used a 9V battery to extend the flap motor. The description of the wires in the manual is a bit confusing but then read online that it is the two larger wires; makes sense. Once extended, measured the length of the rod end bearing per plans and confirmed adequate thread insertion. A little locktite on the jam nut and torque sealed it.

Took advantage of the warm weather today and went ahead and primed a batch of miscellaneous parts in the tunnel and rudder pedal supports. Once that was dry, installed the flap motor. Don't believe I had the AN4-12 bolt that connects the flap motor to the crank in the kit so will need to order one.

[Update - shouldn't have done all of this yet. It all has to come out to put the rear floor pans in.]

  Oct 29, 2023     40-2 thru 40-4 & 40-6: Starting on flap controls - (2.5 hours)       Category: 40: Flap Sys

Match drilled the flap torque tubes. Used the W-706 jig to set the clocking per the plans. Pretty easy. Primed the inside of all the pipes.

Cut the first couple of UHMW blocks and trial fit them to the torque tubes. As expected, they are very tight. Will need to play with heating the blocks and/or chilling the torque tubes to facilitate installation.

Jumped ahead and trial fit the flap motor. Deburred the bracket pieces to be ready be priming.