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Jeff & Jackie's RV-8 Project
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Date: 10-15-2006
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Number of Hours: 3.25
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Manual Reference: 7-11
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Brief Description: Left flap, FL-406x brackets
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Started fabricating the FL-406x brackets today and, as usual when you just get stuck into these things, it wasn't nearly as bad as I expected. First I marked the AS3-125 flat sheet with two FL-406B brackets. I did this by cutting out a full size paper template, marking the corners and joining the dots. I had to place the two templates at an angle to be sure of getting both brackets out of the one piece. Next I got close up and personal with a hacksaw, a vixen file and the scotchbright wheel, at the end of which I had a passable looking FL-406B bracket. Next up, I cut and shaped the FL-406A bracket, making sure it fitted nice and snug into the spar channel. To bend the required 88 degrees (yeah right!) I popped it in the vise, suck a 4x2 on top and belted it with a hammer; job done! With those two bits made, it was time to fit them to the flap. First, I drilled 3mm pilot holes in the front face of the FL-406A bracket and 3mm pilot holes in the front edge of the FL-406B bracket. I cleco side-gripped the two brackets together, postioned as required, and then drilled #30 the FL-406A angle to the front spar, holding in place with cleco's as I went. Next I drilled the FL-406B bracket to the FL-406A bracket through my pilot holes and cleco'd that too (removing the sidegrips, obviously). With that done, I removed FL-406B and drilled 3mm pilot holes along the bottom edge that will attach to the FL-406C bracket. And this is where I hit a snag. The drawing calls for the FL-406C tapered angle to be fabricated from 3/4 x 3/4 x .063 angle. I don't seem to have any. What I *do* have is an 8" length of AA6-125x1x1 angle. Obviously this piece of angle is both larger and thicker than that called out by the drawing. Not only that, but being only 8" long it isn't long enough to make two brackets from, since each FL-406C bracket is approximately 4+7/8" long. I've emailed Vans and basically work stops now until I get an answer; I need to study for that exam any how. More pics follow in next log entry...
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Marking out the FL-406B brackets
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It's a hacksaw job!
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We're done (except holes)
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