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Date:  8-30-2006
Number of Hours:  3.10
Manual Reference:  
Brief Description:  Finished drilling right flap

I went to Home Depot during my lunch hour and found a good flat surface for aligning the flap. I found a luan hollow core bi fold door in the defect bin for $13. As far as I can tell, it is pretty flat, and I only needed one side. It is 6' long and about 18" wide. Perfect for my purposes. I weighed the flap down on the flat surface and then drilled out the skin to the bottom of the flap spar and the flap hinge. I located the hinge by bending it up 90 degrees and placing the angle against the edge of the bottom skin and spar. Then, I drilled out the hinge, clecoing as I went. Then, I fit the top skin on the spar and ribs. It fit perfectly since I bent the trailing edge last night. I then turned it over and drilled out the top skin to the ribs and the spar. I could not weight it down flat on the surface, because it had clecoes in the bottom side, but if all the clecoes are the same size, they should have kept the flap the same distance off of the flat surface, keeping it (relatively) flat. We'll see once it is all riveted. I then fabricated the flap actuator bracket like the left one, except this one was much easier since I already knew the drill.
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The right flap, weighted down flat to the hollow core bi-fold door

The right flap, weighted down flat to the hollow core bi-fold door

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The hinge (on the right edge) turned up to get the right spacing for drilling

The hinge (on the right edge) turned up to get the right spacing for drilling

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The flap actuator bracket after fabrication

The flap actuator bracket after fabrication

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