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Wendells RV-6A
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Date: 3-15-2011
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Number of Hours: 4.00
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Manual Reference: New Left Flap
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Brief Description: Completed Left Flap Construction
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I'm so happy I could just chit --- and chat. The new left flap has been fully drilled and clecoed. When I mounted it again and stretched a string tight along the trailing edge of the aileron and flap, so the string just barely touched, they matched exactly, perfectly. Not even so much as 1/64 error. So, the procedure was as follows. DON'T start with flush alignment of spar and bottom skin edge.
1. Measure and trace correct rear edge of flap spar onto bottom skin. (.10" back on mine).
2. Clamp flap spar in place and fit ribs. Match drill rib bottom plus 2 #30 holes through spar to inner ribs. Outer ribs get 3 #30 holes. Inboard rib holes get match to flap hanging hardware bracket.
3. Use lower #30 hole in each rib/spar to guide 12 inch #30 to drill the back of the rib to the back of the bottom skin.
4. Trim bottom skin flush with spar if necessary. Make 3 part flap attach bracket on inboard end.
5. Drill 55 1/2 inch hinge to flap spar. Be sure the eyes are fully forward of the spar/skin edge..
6. Mount flap bottom and clamp hinge to wing skin at both ends. Outboard end needs to have a narrow clamp. I ground a 2 inch C-clamp down thin enough to fit between flap and aileron bracket.
7. Make sure the flap bottom can pivot to near 90 degrees without interference with wing skin.
8. Verify1/4 inch gap between aileron and flap.
9. Mark, drill hinge onto wing skin. You may have to trim some bottom wing skin. Should be 5/16 inch gap between wing and flap skins.
10. Slip top skin into place over the bottom with duct tape plus spring clamps over each rib end.
11. Adjust top skin up/down to exactly meet the aileron trailing edge,
12. Start at center of overlapped top skin/bottom skin and drill #40, watching the string alignment.
13. Remove flap. Put into V jigs and match drill top skin from center trailing edge up and out. Then across top spar, center then out. Your situation my differ...
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Left flap ready to dimple, countersink, prime and rivet.
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Finally!! Exact perfect match. Yeaaaahhhh.
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Inboard end string alignment is perfect.
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