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Debo Cox - Zodiac 601 XL
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Date:  6-9-2006
Number of Hours:  2.50
Manual Reference:  6W
Brief Description:  Flap Rivet Line Layout and Trimming

Received the flap skins from ZAC. Rivet line layout of the right flap went quickly. I took my time and measured twice, and it still didn't take long. Flap construction is pretty straightforward, and it looks like it will go pretty quickly. I ordered some nylon material and piano hinges from Aircraft Spruce, so I pretty much have all of the parts on hand to finish these up. I've found that for precise, craftsman-like work, a couple of hours is about my limit. After that, I start to get in a hurry and make mistakes. Also, for trimming the skins, I've found that the metal shears work well for taking away large areas of metal, but my Dremel with a cutting wheel does a very nice job of getting nice, undamaged, straight cuts. After using the wheel, I use a file and get the edge nice and smooth, then use some maroon scotchbrite to make a nice smooth edge. Looks like they came from the factory.
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Outboard rib rivet line layout

Outboard rib rivet line layout

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Flap skin

Flap skin

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Inboard end trimmed to fit close to fuselage

Inboard end trimmed to fit close to fuselage

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