The manual says that the flaps are the easiest control surface to construct-I dislike the flaps as much as I do rolling leading edges!
I got started early with the etching and priming to beat the afternoon forecast of rain. The primer dried quickly and I clecoed the spars together and got them into the jig for riveting. I then commenced to beat the heck out of the flap skins (only on top, of course!). I should have had Ginger shoot the rivets while I tried to cram my hand inside the flap with a bucking bar. The painter (me) is going to have some filler work to do. I got them done, but I am disappointed in the result. Pulling the blind rivets attaching the ribs to the spars was not much fun, either. Both of my rivet pullers were a little too tall to fit under the bend of the top skin. Trying to hold the skin back while pulling with the other hand still resulted in a few crimped areas.
I went inside for the night, and something told me that I had dimpled the flap brace weeks ago and perhaps that should have been countersunk so the wing-side hinge would fit flat. I went back out to the garage and sure enough, I had dimpled the brace. I need to do some research on how best to proceed. I think Checkoway may have done the same thing and then countersunk the hinge and added a strip of .025 on the back side for support.
