I forget how tedious preparing a part for riveting is. Every edge needs smoothing. All corners need rounded. All holes deburred (ugh) both sides. Every hole... Outer surfaces get dimpled. Ribs get dimpled and the pop rivet dimple diie comes in real handy. You actually have to slightly bend out the flange at the narrow end of each rib to get the dimple die nail and rivet set inside the small space at the end of each rib. That tool worked great. Countersink every hole in the flap spar on top and bottom flange. That allows you to not mess around dimpling or countersinking the hinge. The hinge is fairly soft aluminum. Regarding the hinge. Mark it at 55 1/2 inches. Pull the hinge pin. Cut the hinge. Until you are settled on how you want to secure the hinge pin, don't cut the hinge pin yet. If ou decide to cut it in half you might need about 2 inches extra for each half to bend the pin and secure it to the flap spar with either a hinge eye or a screw clip into a nut plate on the flap spar. It looks like I will have to remove two or three hinge eyes in the middle area to feed the hinge pin in from the middle to each end of the flap. Countersinking was fun and easy, once you set the depth correctly on some scrap. Don't forget to countersink #30 the bottom of the small angle that fits in the last rib as part of the flap brace. It goes inside the last rib flange which you dimpled #30 for the 1st 5 holes. Also, no dimpling the flap brace hardware or no dimpling the #30 hole in the back of each inner rib. Those get AN470s, not flush rivets Tomorrow I repeat the process on the 2nd flap and then prime everything.
Flap spar gets countersunk both flanges
Cleco to table as I progress with countersinks
Pile of aluminum... Every flap part is complete and ready to prime and rivet.
