With the parts dimpled, and the sub-components riveted together, it was time to begin final assembly of the flap itself. I had read ahead on the plans and realized I needed some new drill bits for the blind rivets. I ordered a #33 jobber bit but didn’t realize I needed a long bit to clear the hinge plates on the nose ribs. Another order submitted for a 6″ bit. While I was at it, I also decided to purchase a close quarters rivet pulling wedge vs fabricating one.
I did have a “manual to implementation” issue with the flaps (Things got lost in translation in my grey matter). I misread / misunderstood the order of operation and ended up blind riveting the bottom skin to the ribs BEFORE I installed the trailing edge. While not the end of the world, it did make the installation of the wedge a bit more difficult than it needed to be. (The flap looks straight so far, but will check and verify against the other flap to make sure.) Worst case is I build a new flap at some point. (wont be the first thing I have to re-order!)
I also had a new tool that I decided to try out – a Trailing Edge squeezer set from cleaveland tool. Instead of setting the double flush rivets with a backrivet plate and a flush set in the rivet gun, you use these angled rivet sets in your squeezer that are aligned with a large safety pin? It’s hard to describe, but it seems to work. Between this new tool and my out-of-order assembly I’m waiting to decide if my flap trailing edge is really as straight as it should be. (I’ll also have some EAA chapter friends give me some feedback).
With everything done, I then press-fit the bushings in the wing side flap brackets (don’t do this unless you are done with the bottom skin), and install the flaps. All look good and I’m excited for another component to be completed. At this point I just want to mark the wings as done (or done for now). Still need to complete the other Flap, finish sealing the tanks, and make a decision on the bottom skins.