Flaps are done! It might be just me, but these seemed to take a long time for how simple their construction was. They are big (probably 8' each), so there was just a lot of time spent to get through all that deburring and drilling. The day dad and I spent priming was a big one too, about a 9 hour job.
Now that the wings are mostly done, I'm sure glad I did both wings at the same time. I couldn't imagine being at this point then having to go do it all over again. There was definitely some economy of scale advantage to getting both knocked out at the same time. I didn't always keep both wings in step-by-step lock though, only doing what made the most sense at the time. For example during the leading edges, I only had enough room for 1 on the bench. So I would get a long ways ahead on one and then catch up on the other just to save me from moving them around a lot.
The flaps were pretty easy. No stainless pipe to deal with like the ailerons. Lots of blind rivets. For the trailing edge I used my trusty old door and angle iron. Even though the flap overhung the iron by over a foot on each side, it still ended up arrow straight.
The first thing you do is create the big flap hinge brackets. Its a little confusing as to how they go together L/R wise when you start on the Left wing, but in the end you figure out they are pretty much the same no matter what wing they are on.
The instructions have you put the bolt and associated hardware into the brackets to forcefully line them up before drilling. I've read where others paid the price for not doing this, so I obliged. Getting those washes in between the brackets can be a bear. Luckily my mom gave me these left over surgical forecepts over 20 years ago. I still have them because they are handy as heck.
Priming was a big job, because I scuff everything with scotchbrite first. These little ribs just kill you, luckily Dad shared the pain with me.
I'm pretty sure these are the biggest rivets I've used so far. AD470 4-10. They go through the middle flap brackets which are a big "sandwich" which consist of 6 pieces, the middle two being really fat.
My buddy John (RV-14 builder) borrowed me this trailing edge jig. You put the extruded trailing edge piece in there and it makes it flat so you can countersink it with a drill press. Here I'm holding it to the drill press table with a couple of clamped boards. WHY did I not have this for the empenage? What a no-brainer, this thing was awesome. If your reading this and are still working on the tail, just buy it.
Here's the internal structure all riveted up. I had to use the double offset set to get some of those rivets. With that epoxy primer on this stuff, assemblies like this should not see the light of day for 100+ years.
Leading edge skins going on.
Now that the wings are mostly done, I'm sure glad I did both wings at the same time. I couldn't imagine being at this point then having to go do it all over again. There was definitely some economy of scale advantage to getting both knocked out at the same time. I didn't always keep both wings in step-by-step lock though, only doing what made the most sense at the time. For example during the leading edges, I only had enough room for 1 on the bench. So I would get a long ways ahead on one and then catch up on the other just to save me from moving them around a lot.
The flaps were pretty easy. No stainless pipe to deal with like the ailerons. Lots of blind rivets. For the trailing edge I used my trusty old door and angle iron. Even though the flap overhung the iron by over a foot on each side, it still ended up arrow straight.
The first thing you do is create the big flap hinge brackets. Its a little confusing as to how they go together L/R wise when you start on the Left wing, but in the end you figure out they are pretty much the same no matter what wing they are on.
The instructions have you put the bolt and associated hardware into the brackets to forcefully line them up before drilling. I've read where others paid the price for not doing this, so I obliged. Getting those washes in between the brackets can be a bear. Luckily my mom gave me these left over surgical forecepts over 20 years ago. I still have them because they are handy as heck.
Priming was a big job, because I scuff everything with scotchbrite first. These little ribs just kill you, luckily Dad shared the pain with me.
I'm pretty sure these are the biggest rivets I've used so far. AD470 4-10. They go through the middle flap brackets which are a big "sandwich" which consist of 6 pieces, the middle two being really fat.
My buddy John (RV-14 builder) borrowed me this trailing edge jig. You put the extruded trailing edge piece in there and it makes it flat so you can countersink it with a drill press. Here I'm holding it to the drill press table with a couple of clamped boards. WHY did I not have this for the empenage? What a no-brainer, this thing was awesome. If your reading this and are still working on the tail, just buy it.
Here's the internal structure all riveted up. I had to use the double offset set to get some of those rivets. With that epoxy primer on this stuff, assemblies like this should not see the light of day for 100+ years.
Leading edge skins going on.
Top skins
The plans have you back-rivet the two aft-most rivets in the top skin. DONT DO THAT - its super easy to screw up. The squeezer works perfect for this job, and its way easier.
The leading edge skins and the bottom skin is all blind-riveted. These are the rivet tails from just 1 flap!
