January 21, 2005 - Right Flap |
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| Let's start the right flap. I've already de-vinyled and edge-smoothed the spar and skins. First step is to cleco and match-drill the ribs to the spar, as shown here. | ||||||
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Then cleco and match-drill the bottom skin to the ribs.
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| Then match drill the Hinge to the bottom skin and bottom spar flange. I marked the hinge so I have 3/16" between the hole in the hinge and its edge. This was to facilitate aligning the flap trailing edge with the aileron trailing edge down the road. | ||||||
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I don't have any pictures, but next I fashioned shims that go between
the top skin and the end ribs. I also fashioned little shims that
go between the rib ends and the "virtual" rear spar. These shims
may be little, but the little rib-end ones are kind of a pain to make.
Next, I clecoed and match-drilled the top skin to the flap structure.
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| Now it's time to fashion the famous FL-706A flap spar reinforcer. No pre-made component from Van's here. You get to do it yourself from the supplied aluminum angle material. A lot of sawing with the hack-saw. (Editor's note: this is when you wish you had a band saw, isn't it?) Then measuring and drilling. | ||||||
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| The completed FL-706A flap spar reinforcer on the left. Van's supplies the FL-706B on the right. All you have to do is bend it a little bit. Which is easier said than done, since it is 1/4" thick. I put it in the vise, then pushed hard, while Lynnette pushed back on the workbench. | ||||||
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| Cleco the reinforcers to the spar and end rib, and more match-drilling. | ||||||
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