1.8 Hours -
The first thing I did this evening was redo the small shims that go between the interior flap ribs and the rear spar. The original ones were probably fine, but I wanted to make them just a bit bigger. Measuring the pieces took only a few minutes…cutting and finishing them was quick using the band saw and Scotchbrite wheel.
Next, I flipped the flap over and drilled the bottom skin to the ribs. Once the bottom skin was drilled, it was time to attach the hinge. Piano hinge is used to attach the flaps to the wings. The hinge runs the full length of the flap spar much like the hinge that was used to attach the trim tab to the elevator during empennage construction. To make sure I was keeping the hinge straight, I drew a line down the center of one section of the hinge. Once the hinge is clamped to the flap, I just have to make sure the line is visible through the holes in the skin/spar. As long as the line is centered in the holes, I know the hinge is straight.
I marked the middle of the hinge stock to aid with alignment on the flap.
The hinge clamped to the left flap. I cut it to length after it is drilled.
Here, my line is visible through the holes in the flap. As long as I can see that line, I know the hinge is straight.
After drilling the hinge to the flap, I clecoed on the top skin and drilled it to the rest of the structure. All that is left is to take everything apart, deburr and dimple the holes, and rivet everything back together. My plan is to finish the left flap, including mounting it to the wing, before I continue with the right flap. This way, I know my construction technique was correct before I move on to the other side.
The left flap with the hinge and top skin clecoed on.
