Wings part 40

Got started on the flaperons today.

Apparently in the past, Van's expected the builder to whittle these parts out of various extrusions.  I remember doing similar types of task when I built my 7 and parts of the 10.  Old builders try not to be too upset that Van's now provides these parts pre-manufactured and beautifully anodized.  They even tap the holes for the hinge bearings!

The KAI's state to flute these tip ribs to get them as flat as you can.  These guys take some serious flutes....  You can't get them perfect and the plans state to just do the best you can.

These other ribs do not need as much of a flute.

There are allot of lefts and rights on these so be careful to keep it all straight.  It would be easy to screw it up.  

These outboard nose skins need to be match drilled to the stainless counterweight pipe.  This requires a good drill bit and some lube.  Don't overheat the bit or the pipe as stainess can become almost impossible to drill if you do.  Take your time and find the right speed to keep the bit cutting.

Also be aware that this nose skin has a hole in the bottom that must align with the bracket for the hinge bearing.  It would be easy to get the wrong skin on the wrong flaperon.

Match drilling the other side.

Then they have you take it all apart, deburr and then rivet the ribs to the counterweight using the two holes that were just drilled in the pipe.  You must bend the flange a little on these ribs to get the rivet puller in there.  I also squirted a little primer on matching surfaces to help prevent dissimilar metal corrosion.  I will prime the whole thing later in the process.

Other side done.

Then they have you put it all back together and match drill the nose skin to the counterweight.  Be careful to align the drill so that the bit does not walk...

Then they have you match drill the remaining holes on the ribs to the nose skin.