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Patrick Kelley (Flion)
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Date: 8-1-2015
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Number of Hours: 5.00
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Manual Reference: 40-2 to 40-5, 40-8
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Brief Description: Build and install flap torsion arm.
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Building the torsion arm was simple, just following the instructions. I drilled #30 by hand, and #12 on the drill press. In Image 1 you can see that I used a long drill to make sure opposing holes lined up. I did change the sequence a bit; in Image 2, rather than remove the jigged part and risk it moving, I drilled the three holes I could reach #30 and put clecos in, then drilled the remaining hole before taking the assembly to the drill press to drill out to #12. After that, I hand-drilled to 1/4" and installed the bolts for test.
Installing was much more difficult. My buddy Phil Cobbin had machined the UHMW blocks for me, so that was no problem. But the holes on the outer skin were too small to pass the tubes so that had to be carefully filed out. Then, reaching in to do the bolts for the blocks that were between the side skin and inner cabin skin was very difficult; my hands are to big for that area. I got the center arm in and bolted in place and then decided to do the outer arms before installing the flap motor. Getting the bolts in wasn't too bad but then getting washers and nuts on them in that tight area turned out to be more difficult than the bolts for the blocks. Persistence paid of and it's now in - hopefully to never come out,
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