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Date:  12-23-2007
Number of Hours:  5.00
Manual Reference:  6W1 8-9
Brief Description:  Attach hinge to left flap

1. Cut hinge to 1983-mm with hack saw, deburr the cut edges.

2. Grind hinge pin so that it is ~15-mm shorter than the hinge

3. Procedure for drilling piano hinge for safety wire:
- Drive hinge pin about 10-mm into one end of the hinge
- Place hardwood clamps on the kit storage shelve legs to support the end of the hinge
- Put 1/16" bit in drill press
- Adjust press table height to drill hinge supported on a piece scrap 2x4
- Clamp hinge to 2x4
- Punch the top of the hinge, ~3-mm from the end of the hinge
- Begin drilling the hinge, extremely slowly, so that the drill bit does not wander sideways on the hinge
- Repeat for the other end of the hinge

4. I drilled the hinge perpendicular to the flattened hinge. But when I placed the hinge into position, I saw that I should have drilled parallel to the flattened hinge. Access to the holes for the safety wire will be obstructed by the front of the elevator when the hinge is riveted in place. I need to redrill the hinges. The extra holes should not be a problem if I drill very carefully.

5. Removed the two end-ribs from the flap and clecoed it back together.

6. Marked the rivet line on one side of the hinge. Taped the hinge onto the front of the elevator and marked the location of the rivet hole for each rib. It took some forethought to get the hinge oriented correctly w.r.t the flap.

7. Used a rivet fan to mark the intervening rivet holes. The 40-mm spacing fit perfectly between the interior ribs, but needed adjustment at the two ends of the flap. The spacing was slightly greater than 40-mm on the outboard side, and was ~30-mm on the inboard side.

8. At each end of the front of the elevator, I placed a clamp to keep the flange from slipping down past the correct height. Then I clamped the flange to the front of the elevator, and clamped the elevator to the steel beam at each of the ends. See Fig. 2.
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Set up for drilling hinge for safety wire

Set up for drilling hinge for safety wire

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Elevator clamped for drilling

Elevator clamped for drilling

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Drilling the elevator hinge

Drilling the elevator hinge

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