Flap varnish

Applied epoxy varnish (mix used was 1 part varnish, 1 part catalyst, and 3/4 part reducer) to the wood surfaces of the flaps. We then waited for them to dry about 30-40 minutes, and applied a 2nd coat of varnish.  Hours=1.5

Fabric backing plate work for flaps

We measured and positioned the fabric backing plates on the flaps, then drilled the holes for the attaching rivets.  Next we removed these plates, countersunk the holes on one side (since we will be using countersunk-rivets), and deburred the parts.  Hours: 1.5

Flap Pre-Fabric Work

For the flaps, we decided to switch jobs.  Ed worked on creating the aluminum fabric backing plates.  They were created based on templates in the builders manual.  A total of six backing plates were made.  Mike located and drilled the flap ribs for the fabric rivets. Three holes on the top of each rib and three on the bottom of each rib.  Hours: 3

Ed fabricating Backing Plates

Mike Drilling Flap Ribs

Three Holes per Rib

Aileron fabric backing plates

Permanently attached aluminum fabric backing plates to the ailerons by applying a thin layer of Hysol adhesive, and riveting in place. The next day, after the epoxy had cured, we applied lightweight 2-part filler to smooth the transitions between the fabric backing plates and the surfaces beneath them.  Hours: 3.0