Flaps with filler added

Applied lightweight 2-part filler (a 3M product that is similar to Bondo but lighter) to fill in some defects (voids) in the leading edge of the right and left flaps.  Also added some filler to smooth the transition on the flaps between the ribs & leading edge, and between the ribs & trailing edge.  Excess filler has not been sanded yet.  Hours: 2.0

Lightweight filler added to left flap

Epoxy Touch-up

A small batch of the Hysol epoxy was mixed up and applied to a few areas on the flaps and ailerons that had come loose during the cutting of the leading edge fiberglass.  Once it started to setup the areas were smoothed out for a better appearance. Hours: 1

Aileron/Flap Work

We completed cutting the slots in the leading edge of the two remaining control surfaces.  We also noticed a few places that will need some epoxy touch-up between the false rib and fiberglass leading edge. Hours: 1

Aileron and Flap Work

We sanded the wood cap strips on each of the ailerons and flaps so that there is a "nice" transition between the cap strips and the fiberglass leading edge.  We used various methods to get the "nice" transition, sanding blocks, orbital sander, and Dremel multi-tool.  Once we had the transition correct we started working on opening the area around the hinges and control attach points.  We cut most of the material away using the Dremel multi-tool and then finished using files.  We got 3 of the 4 parts completed before stopping. Hours: 3

Ed sanding the Cap Stip with the Dremel Multi-Tool

Bottom of Flap with Fiberglass Removed from Control Hinge

Top of Flap with Fiberglass Removed from Mounting Hinge

Attaching Flap and Aileron Leading Edges

Leading edge epoxied in place, and held temporarily with tape

Using Hysol epoxy, we attached the remaining false ribs to the right flap.

Then, we cleaned and prepped the aluminum aileron and flap spars, mixed up some more epoxy, and glued all of 4 of the leading edges to their respective flap or aileron (both right and left sides).  There are 6 primary ribs, and 14 false ribs for each piece, so a total of 20 epoxy attach points for each aileron and flap.  Once the epoxy had cured for about 30 minutes, it was smoothed to make nice filets.  Hours: 3.0