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First thing on the docket today was to make these flap braces. It's the green thing in the picture below. They started the day as a single chunk or angle that I cut to size in width (to fit between the spar flanges) and height (the tab parallel to the spar web with no holes drilled in it). I used a jig saw to make the cuts and it worked amazingly well! After cutting them, all it took was a couple quick passes on the bench grinder to get them perfectly made to size. I then drilled the holes in them. This took a little care getting done correctly. After I got them drilled and primed, I riveted them to the spars.  It was tedious drilling the holes correctly (mentioned earlier) because the flange on the flap brace butts against the five holes on the end of this side brace things... but, these side brace things have to be bent to 6.3˚. These side braces are beefy so I had to take my weekly trip to Home Depot and buy a vise to help with the bending. When I got the drilling of the flap braces and side braces all worked out, I riveted the side braces to the end rib.  All this took lots of head scratching because the instruction for the flaps suck. I ended the day by debluing the skins and started deburring all the parts. I managed to debur the ribs, the spars and the hinges but didn't get to the skins so I got that to look forward to.
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| Thanks for visiting! | Last Update: 25 May 2012 |