| September 5, 2007 |
| Flaps |
 |
 |
| Getting back in the grove. Feels great! I already had the flap prebent skins from the Formed Aluminum Kit that Sonex offers. Flaps seem rather simple. You have 4 ribs for each flap, a hinge to cut and drill, and a flap control drive that needs riveted to a rib. (The flap control drive is not shown) |
 |
| Flap control drive already has lightening holes. We drilled them out to #40 and cleaned the parts up with a flap wheel on the drill press. |
 |
| Measured where the flap drive goes on the inboard rib and clamped and drilled. Used the holes already in the control drive as reference. |
 |
| Here are the Left & Right inboard ribs with their associated drive horn. Drilled everything to #30, cleaned, then primed. |
 |
| While waiting for the primer to dry, I got started measuring and cutting the flap hinges to correct length. Then dad & I drilled the 140 holes in this thing. Goes fast enough with the hinge guide we made for the tail pieces. we have NOT regretted making this! In case you missed it -->. Hingeguide1 Hingeguide2 |
 |
| My new deburring tool. A Harbor Freight cordless electric screwdriver with a deburr head JB welded to a 1/4" hex drive. Tonight showed it was a good investment. I will probably buy another so dad and I can both deburr with one. We always fight over the deburring tools! |
 |
| Hinges deburred and the flap drive assemblies are riveted. I have an Inguinal hernia surgery tomorrow. So I might be out of commision for a few days! Just when everything was going good! |