21-01 -> 04: Preparing Flap Structure Components

 Flap Hinge Brackets

The flap work started as always with some match drilling, fluting and edge deburring lots and lots of ribs. 

Flap Hinge Brackets were bent so that they were parallel to the flanges.

The flap hinges will be double flush riveted at the trailing edges, so need some holes marked onto the left hinges. This was a little confusing at first - what the plans mean is the left bracket of each pair, not the brackets on the left flap. So there are 4 brackets in total which are marked up for holes - the other 4 are match drilled later (once the flap is clecod together). 

As an aside, i received 6 flap brackets in my kit - despite the plans inventory stating 4. I believe the RV10 flaps are longer and have 3 bracket assemblies per flap - so they must just make up bundles of 6 and send the same bundles to -10 and -14 customers.

Flap hinge flange holes were marked on the left brackets. 

Once the first left bracket was drilled, it was placed on top of another left bracket and match drilled.

I used a 1/4" reamer to ensure that the bolt holes were aligned on both parts when match drilling. 

Don't mix up the parts

The 2 flaps are mirror images of each other, and i decided complete both flaps at the same time. In order not to mix up the parts, i laid out the parts for the left and right flaps in the correct order from inboard to outboard, and labelled each rib L1 - L8 with L1 being the most inboard rib. Where a nose rib had a doubler or a flap bracket, this was labelled with the rib number this attaches to. Eventually these numbers will be transferred to some little aluminium tabs, which i will keep on the parts with a cable tie for prep and priming. 

Each nose rib needed a single flute only

Then many hours of deburring each nose rib....

Flap Ribs

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The flap ribs were laid out and labelled in the same manner

Example of flap numbering

Each rib needed a small tab cut off on the top side - i clamped my dremel with a thin cut-off disk in order to do this 

Then once again - many hours of deburring

The spars were also deburred...

... and both flap structures were clecod together for the skin preparation next.