Flap Motor Arm Cover

Problem: The flap motor arm extends into the fuselage interior

The flap motor arm was safety wired as per Vans service bulletin.

Solution: Make a cover for it. It's held in place by 3 hidden #8 screws and nutplates.

Test Run of the Electric Flaps

It feels good to have something move on it's own for a change!

Flap Push Rods

Left side flap push rod. The rods had to be cut,drilled, and tapped.
Lots of trimming around this area....The flaps now sit nice and flush when in the up position. Sweet!

Right side flap push rod. The holes on the fuselage had to be enlarged to prevent interference with the rods...

Flap motor gets a test run...

Flaps Get Fitted to the Wing!

Well I spent most of the day today getting the flaps all lined up and trimmed to perfection.
Udo came by once again to help ease my frustrations and lend a hand. This is definitely a two man job. I waited until the wings and ailerons were mounted to drill the wing side of the flap hinge.

Flap in the up position. The inboard edges needed a little triming. We used a die grinder w/a scotchbrite wheel and files to do the job

Trailing edges all lined up. This is the real challenge.

I removed several eyelets and installed a hinge pin in both the outboard and inboard sections. I will drill two small holes and safety wire the ends down. They are only accessible when the flaps are all the way down.....

Wing side of the flap hinge all drill and clecoed in place. Be sure to back up your drilling with a piece of wood to get nice straight holes... We also had to temporarily safety wire the flap brace down to aid in getting the hinge lined up. Yes, a real pain. Glad it's done!

Total Time To Build The Flaps

Ava, Ford, and myself celebrate the completion of the Flaps!

Both Left and Right Flaps are complete and cleaned up!

Total Time To Build The Flaps
2008 - 37 Hours

Right Flap Complete!

Right Flap Assembly Pt.2

Right inboard rib shown with support bracket and AN4 nutplate(hole near end of bracket) riveted in place.

I used proseal on the trailing edges of the inboard and outboard ribs. This should add support to the pop rivets and spacers that were used at the trailing edge. No, it's not mandatory, but I had a little left and decided to use it.

Here the top row and spar to ribs rows have been riveted. Bottom row is clecoed with hinge in place.

I finished things off by riveting the two support brackets together with AN470-4-7 rivets. (rivet tails shown). I also touched up any scratches with rattle can aviation primer.

Right Flap Assembly Pt.1

Right Flap skeleton. Check plans to ensure correct placement of ribs.

I clecoed everything up, then removed the spar for riveting access.

Inside shot. I used pop rivets LP4-3 on the rear rib to rear spar connection. The marks are duct tape smears from the bucking bar. Yes, this is a tight and painful area to rivet.

After the ribs are riveted, I reinserted the spar and clecoed it up. This was followed pop riveting the spar to the ribs, then solid riveting the top and bottom rows. Don't forget to fit the hinge in place before riveting.

Left Flap Complete!

The Finished Left Flap.

Inboard Side. The wire for the hinge will get trimmed at a later date.

Outboard side.

Final Assembly of the Flaps Part2

After the ribs, platenut, and rib support bracket have been riveted, I reinstall the spar. The spar then gets pop riveted to the ribs with LP4-3 rivets. I also used proseal and flush structural pop rivets to secure the trailing edge shims to the inboard and outboard ribs.

Next, I riveted the spar to skin rows. The bottom row gets the hinge riveted as well.

Final Assembly of the Flaps

Inboard Left Rib is clecoed in place. Spar support bracket has been riveted.

All ribs and skins clecoed up. The spar gets removed to allow for riveting access.

Left Flap Assembly in a "V" shaped jig for alignment and riveting.

Primed Aileron and Flap Parts

Aileron and Flap parts after the acid etch, alodine, and two-part epoxy primer.




The past two days I have been prepping and priming a ton of parts and pieces. I have all remaining skins, aileron, and flap parts ready for final assembly.

Final Drilled the flap skins

I final drilled all holes Left and Right. I used a #41 reamer on the skins

Flap Spacers and Flap Hinge

Fabricated the flap spacers

Drilled out the flap hinge. Be careful on edge distance.

Started Drilling Out the Flap Parts