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Date:  1-9-2010
Number of Hours:  6.00
Manual Reference:  
Brief Description:  Flap Aft Access Panel 1

I enlarged the aft flap support bracket access panel, so my size #9 hand would fit behind the flap torque tube in order to hook up the main fuel tank vent nipple. There just wasn't enough room for the standard Avipro access panel to accomodate my relatively large hands. I thought about having my wife hook up the vent nipple, but what if she's busy? I made the rings the old fashioned way without a router as I only had to make two of them. A Dremel metal cutoff wheel was used to cut the inner hole of the ring and the skin cutout, and files were used to true and clean it up. I placed a slightly oversize piece of aluminum over the cutout hole and marked it with a fine Sharpey and trimmed the aluminum with a shear and belt sander. The forward and outboard ring rivets have half spacing in comparison to the other sides in order to minimize skin oil-canning. I predrilled the ring, centered it on the hole, and drilled the ring rivet holes from inside out. It was necessary to remove the torque tube to flap arms and back the torque tube out, in order to get the rivet squeezer into position. I also made the left wing ring and trimmed a piece of slightly oversize aluminum to make the other side quicker to install.
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Ring centered in wing skin access hole.

Ring centered in wing skin access hole.

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Outside view.

Outside view.

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Inner view.

Inner view.

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