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Date:  9-11-2006
Number of Hours:  3.10
Manual Reference:  
Brief Description:  Drilled right flap to wing and drilled out wiring

My buddy Sam Beal came over tonight to help me install the right flap. First, we took the new hinge (which I robbed from the fuselage kit) and pulled the pin to use one side. We then cut the hinge-half to size and pinned it to the right flap. We then installed all of the right spacers and washers onto the right aileron attachments so that the aileron would be correctly positioned side to side. Next, we aligned the flap 1/4" from the aileron with the trailing edges of the aileron and flap also lined up. After checking edge distance on the flap hinge, we clamped everything down and drilled the flap hinge to the flap brace. It looked good. At this point, I had some head scratching to do. I had previously drilled all of the wing ribs for wiring conduit near the trailing edge of the wing (you can see these small holes near the trailing edge in photo 1). That turned out to be a bad idea. Even thought the position near the trailing edge seemed ok (it does not interfere with the aileron pushrod) everyone else I have spoken to, including the people at Vans, says that is a bad idea. Those opinions were confirmed when I finally assembled the rear wing spar and found out that the outboard aileron hinge covers about half of the hole. So, I have agonized over where to put the wiring conduit. Sam and I looked at all of the possibilities and decided to put it where other builders have been sucessful, near the bottom skin, between the first and second lightening holes. We drilled a #30 pilot hole in the rib next to the aileron bellcrank and pushrod to confirm that this position would not interfere. Then we constructed a small jig out of an aluminum strip from the trim bundle that came with the wing kit to ensure that we would be drilling the conduit hole in the same location in each wing rib. Using the jig, we drilled #30 pilot holes in all of the wing ribs. For the two interior wing walk ribs, we used a longer drill bit. Then, we used a 7/8" hole saw bit to enlarge all of the holes. A scrap piece of plastic wa
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Sam Beal driling the right flap to the wing

Sam Beal driling the right flap to the wing

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