Flap Construction

Started on Left Flap	August 8, 2004
I had a little time left before dinner (and after finishing the last aileron), so I pulled down the parts for the left flap and started working. For the most part this means only (a) identifying the parts and (b) getting the spar deburred. BUT ... its a start. :) Time : 0.5 hours

Left Flap Deburred / Bottom Skin - Ribs Drilled

August 21, 2004

We had a big break in working on the plane due to a couple of trips that consumed weekends (Philadelphia and Theresa's "Bear Hike"). But I'm back at it, and the flaps go fast. I finished deburring all the edges of the skins and ribs, then assembled the spar/rib/bottom-skin and drilled. I also fabricated the shims needed for two of the ribs where they attach to the rear spar, and for the bottom rear section of the end ribs. Along with all this I positioned and drilled the hinge. It will need to be trimmed to size, but I can do that once I disassemble all this for deburring and dimpling. It looks like the flaps really are going to be quite easy to build. Time : 2.5 hours

Top Skin - Ribs Drilled

August 22, 2004

This morning I first put the needed shims in place and drilled the ribs to the rear spar. I attached the top skin, and drilled the skin to the ribs and spar. I fabricated the angle bracket, and am ready to attach the end reinforcement bracket (after I bend it to the precice 6.3 degrees of bend ... yeah .... right). After a break I bent the reinforcement bracket, and drilled the bracket to the rib along with drilling it's companion (FL-406A) to the spar. I primed the brackets and deburred the ribs along with the ribs and the spar. After some lunch I deburred the skins while Chris countersunk the lower flange of the spar. I did a little head-scratching on the attachment of the flap actuator hardware, and realized that I can't (I don't think) find my CM-4MS rod end bearings. I'll call Van's on Monday and get some on order (or figure out that something I did see really is something other than I thought it was). I drilled for the platenut, and attached one leg to the rib. I riveted (except for where the rib goes) the F-406A to the spar, and then riveted the center flap ribs to the rear spar. I also dimpled everything in sight ... skins, ribs, and the flange of the spar that was not countersunk. This finishes up the parts prep getting ready for riveting. Finally, I build the riveting cradle and clecoed the flap together ready to rivet. There is no time, as family activities finally call, but I should be able to finish up this flap this week. That'll be good because next weekend will be mostly consumed with the trip down to Southport to look at kayaks. :) Time : 8.25 hours

Riveted Reinforcment Bracket / Started Right Flap

August 27, 2004

I riveted the reinforcment bracket to the rib, and also set those few rivets on the end rib that faces inward that I can get to with the bottom skin off. They are impossible to reach otherwise, and even at that I'm going to have to use a blind rivet or two. I also cut the piece of angle for the reinforcement bracket on the right flap. So ... technically ... I've started the right flap as well. Every little bit of progress counts! Time : 0.75 hours

Riveted Left Flap / Deburred Right Flap Parts

September 5, 2004

This morning I got out the parts for the right flap, and got all the edges deburred. Chris helped me get the annoying plastic pulled off of all the parts for the right flaps. This afternoon Theresa helped me drive rivets on the left flap, and then I spent the rest of the time squeezing those that could be squeezed. In the end I had drive the rivets along the top of the main spar, but with access so open I was able to drive and buck solo. Time to really leap into building the right flap now! As a note, Chris also started his new job today. After a little confusion this morning, things got straightened out and he is off working right now. I don't know why I note this in the logbook here, but it seems like a critical milestone to me ... and, one of my better building helpers is going to be more scarce from now on. So that is the connection. Right. :) Time : 5.5 hours

Drilled Right Flap Bottom Skin/Ribs (etc.)

September 10, 2004

I clecoed the bottom skin, ribs, and spar together. I drilled the ribs to the spar (front and rear) and fabricated a few shims for the rear spar where the ribs attach. I laid out and drilled the holes in the reinforcement piece that I already cut from the AL angle. I bent the other reinforcement piece to the ever-so-precice (you believe that, right?) 6.3 degree angle specified in the plans. Time : 1.25 hours

Drilled Right Flap Hinge and Top Skin	September 11, 2004
I positioned and drilled the hinge line on the flap. I then clecoed the top skin in place (including the shims) and drilled the top skin. That was all the time I had today, but hope for more tomorrow. Time : 1.0 hours

Drilled Right Flap Actuator Reinforcements

September 12, 2004

Due to some unfortunate events creating significant distractions today I only got a little done on the flap. I did drill the actuator reinforcement brackets to the rest of the structure. Left to do is some other minor drilling and attaching the platenut for the actuator. Priming the reinforcement components still needs to be done as well. Then it is all a matter of deburring, dimpling, and riveting. The classic sequence of assembly events ... and I'll be done with this flap. It is going much faster (in terms of hours expended) than the first, as expected. Time : 1.75 hours

Finished Drilling Reinforcements / Platenut

September 15, 2004

I finished drilling those last few holes on the actuator reinforcements (the ones which tie the two pieces together), as well as the holes for the K1000-4 platenut. I also drilled the three rib holes which pass through the forward reinforcement bracket. I deburred the reinforcement brackets, scotchbrited and cleand them, and primed them (as well as priming the few shims I needed for this flap). I also got the flap spar deburred while waiting on the paint to dry, but then needed to call it a night. This will likely be the last bit of work I get done until I get back from the trip to San Francisco with Theresa. Time : 1.50 hours

Ready to Drive Rivets on Right Flap

September 26, 2004

I did all the work needed to get the flap ready for driving rivets. I attached the actuator reinforcements, the actuator platenut, primed the shims (which I had missed priming when I did my earlier batch of priming), deburred the ribs and skins, dimpled the ribs/skins/spar as well as doing the countersinking on the lower flange of the spar. I squeezed the four 1/8" rivets which attach the inside ribs to the rear "spar" and squeezed the two rivets I could get to on the bottom skin at the back of the inboard rib. I'll still have to use a few blind rivets just because I'm not willing to fabricate special-case one-time-use bucking bars. :) We are now ready to rivet the ribs to the skins and finish this flap. Time : 4.25 hours

Flaps Finished!

October 3, 2004

The second (right) flap is finished! With help from Theresa today we drove all the rivets. I used the squeezer where I could (on one end rib, and on the lower row of spar rivets, as well as one or two other places) but she and I drove the rest. I cut the hinge pins to length (the right length this time) and set all the blind rivets. I used the handy-dandy pneumatic squeezer to get those AD4-6 rivets that tie together the two actuator reinforcement fittings. I am done with the flaps! Woo hoo! Time to get back to the wings, finish up the tank sealing (which .. yes .. I have been putting off for a while). I have some small odds and ends to finish in the wings (run some line for the pitot/AOA, install the A/P servo, etc.) and we can start to close out the bottom skins. Before you know it, we'll be onto the fuse! NOTE: Don't forget to order a replacement hinge pin when ordering the finishing kit. That way the pin ... which is long ... won't incurr a high shipping charge. In fact, I am going to get about 3x as much as is needed against future need! Done! Time : 4.5 hours

 

Total Time : 31.75 hours 

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