This was a real red letter night in the shop. I spent all night rigging the flaps so that they would go through their full range of motion without the actuator rods rubbing the access holes in the fuselage. Bolting the rod end bearings to the flaps was the first challenge. It is a real tight fit and almost impossible to get the nut onto the end of the bolt which goes through the rod end bearing. I finally figured out that I could wrap my finger with inside out tape and stick the nut onto the end of my finger. I could then squeeze my finger, with attached nut, into the space behind the flap attach angle and gingerly turn the bolt until it got started on the nut. I then finished tightening with two wrenches. Next, I had to gradually enlarge the holes through which the flap actuator rods passed so that there was no rubbing throughout the full range of motion. One end of the flap actuator rod is connected to the flap angle and the other end is attached to the flap motor. I had to run each flap through about 20 cycles, and then grind off a little more aluminum after each cycle. Finally, both flaps would go up and down without rubbing the side of the holes. I was so excited that I dragged Vicki down into the basement and made her watch the flaps go through the full deployment and retraction cycles. Even Bear, our visiting grand dog, seemed to be impressed.
