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Russ Karnap
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Date:  6-30-2019
Number of Hours:  10.00
Manual Reference:  
Brief Description:  Flaps - Deburred edges, Match Drill Left Flap

Deburred all parts for both Flaps including the lightening holes in both spars. Started match drilling the Left Flap parts. Made all four spacers that go under the main rib tips. Bent the Left Reinforcement bracket. VERY HARD to bend. Tried two by fours in the vice, but the plate had a gradual bend for a few inches. Then I tried using the back rivet plate clamped to it, and it helped a lot. Unfortunately, when I installed it and the angle piece onto the spar and match drilled everything, the angle bracket was pulled out past the edge of the spar a little. Had to "slot" two of the holes that mount it to the spar. Then I fabricated a doubler plate out of .025" plate. And match drilled it to the angle. Drilled the 1/4" hole in the end for the bearing rod.

On the right Spar, it's important to make sure the edge of this angle is flush with the edge of the spar. Match drill it before installing the bent angle. This will help determine when it's bent enough too, because I'm not sure how the heck to measure 6.3 degrees!!!

The left Flap is now ready for countersinking, hole deburring, priming, dimpling, and then final assembly. Looks like it's going to be challenging to rivet all this together. The directions say it's one of the easiest assemblies, but I beg to differ....
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