September 10, 2007
Flaps
Made it back from surgery! Although, I am still taking pain killers once in a while. The wife is home watching Grace, so I hate to miss out on this RARE opportunity to work on the plane without worring about the baby crying.

Angled cut needed on the flap skin. This is only done on the inboard section, this is needed because of the tapered fueslage sides.
As you can see we stuck a rib inside the skin for rigidity while making the rough cut with the bandsaw.
After filing the angled cut to the line, we marked the location for the cut-out needed for the Flap Drive Horn (the part that connects to the part that makes it go up and down... make since?)
Made the radius in the right hand corner then used the tin snips and files to make it look kind-of-pretty.
There is a total of 4 ribs in each flap. Each one has the same rivet spacing shown here in the plans. We made a template for the top and bottom skins from the angled cuts we did earlier on the bandsaw.  This should allow for a fast set-up for the many holes we will need to drill.  
The plans tell you the 4 rib  locations on the skin.  Here we are marking the rib locations then making a straight line down the skin where the rib will go.
Both skins marked for the rib locations and associated hole landmarks.  This is simple enough, but it does take time.
Last thing I did for the day was make my center lines on the rib flanges...   The rest of the day was spent with the wife and baby, I did not want to push my luck!!