Today I will start mounting the right flap to the wing. I already have the ailerons mounted and in the neutral position. The quick build flaps already have the piano hinges riveted in place and all I have to do is cut the mating hinge to length and attach it to the flap with the piano hinge wire. I marked and cut the hinge with my cutoff wheel and deburred the edges. I installed the hinges to the flap and then lowered the flap into position on the wing and used spacers to adjust the height so it matched the aileron. I clamped the flap in place and used my six foot straight edge to check the alignment of the trailing edge with the ailerons trailing edge. I found that a gap of 8/32" between the wing skin edge and flap skin edge gave me a perfect alignment. I held the hinge in place with a clamp and drilled the first #40 hole using the holes in the wing skin as a guide. I put a cleco in and went to the next hole. I worked from the root end out and checked the gap as I went. I pulled the hinge pin and lifted the flap away and then removed the clecoes and the hinge. Next step is to machine countersink the flap hinge to mate with the dimpled wing skin and flap brace. I deburred the holes and used a piece of scrap to set the countersink depth. I countersunk all the holes and checked the fit on the wing. DWG 12 calls for AN426AD2-4.5 flush rivets. I clecoed the hinge back to the wing and used the butt end of a #40 drill to make sure the 3 holes lined up before I installed the cleco. I skipped every other hole and put a rivet there. I used my pneumatic squeezer and set the rivets. I removed the clecoes and installed and set the remaining rivets. I set the flap into position and inserted the hinge pin.
