Initial Prep (Debur, Trim, Drill, and Cut)
3/5/23 - 2.2h
3/6/23 - 1.2h
Trailing edge wedges, like the one on the rudder, are provided for the flaps (and ailerons). The flap is longer than the wedge, so a long piece and short piece are trimmed to form a but joint approximately 10 inches from the inboard edge of the flap. The initial cut locations are measured and marked, and then the wedges get cleco'd to the bottom flap skin for fine-tuning. The problem I had was deburring the cut ends of the wedges. The deburring process led to a small, but noticeable gap (less than 1/32” between the wedge pieces. I plan to try again and leave the wedges a little long so the deburred wedges fit closer.

The final task on this step is to put a slight bend in the long edges of the leading edge skins. This is a little tricky because the skins are hard to clamp to the workbench without damaging the bends in the skins. I ended up holding the parts in place by hand, and going very slowly with the edge forming tool. The bend is very subtle and even down the length of the skins, which is what I was going for. I also took this opportunity to debur the edges of the leading edge skins.
[Hole and Edge Deburring Tools, Dremel with Metal Cutting Disk, Edge-Forming Tool]