Final Flap Tapes

The leading edge tape is the final tape to be applied on the flaps.  The tapes needed to be 5" in width.  Since this is an uncommon width we used pinking shears to cut two tapes from left-over scrap fabric.  Three coats of adhesive were added to the leading edge and finally the two edges of the tapes were glued down and the fabric tapes were shrunk with heat for a nice tight fit. Next we will apply additional glue on the leading edge to affix the fabric tape.  Hours: 4

Leading Edge Tape Being Applied

Flap covering

Made quite a bit more progress on covering both flaps.  We glued on all chord-wise tapes, and also installed doilies around the fabric backing plates.  Also fixed a small fabric tear in one location with a patch. We decided to place the drain holes in the aluminum trailing edge, which means we could use the trailing edge tape to protect those holes without adding additional doilies.  We drilled 1/4 inch drain holes in each bay of the flap (in the aluminum piece).  Would have been much easier to do this if we hadn't already covered the flap in fabric, as deburring the metal was a bit of a pain...so this is a lesson learned and we will do this in the right order when we cover the ailerons.

We glued on all the chord-wise tapes, and then attached the 3" trailing edge tape, using irons to smooth it all out as necessary.  Finally, we used an old soldering iron to burn through the fabric at the location of each drain hole.    Hours:  6.5

Flap with most tapes installed, and drain holes added in trailing edge

Round patch being added at location of a small tear

Patch complete, plus other tapes installed

More flap covering work

We measured and drew some pencil lines that are guides for areas that glue will be applied.  We also measured and cut out some protective doilies out of pre-shrunk fabric.  These doilies will be used around the fabric backing plates and drain holes, and they provide some additional protection to the fabric.  Hours: 2

A few misc protective doilies 

Flap fabric covering, cont.

We continued work on covering the flaps this weekend.  We used the extra material on the ends of the flaps to create flaps that we then folded over for covering them up.  We had to cut some V-slots in the curved area of the leading edge to keep everything neat and prevent any folds in the material.  Without knowing exactly how many slots to cut, Michael cut about 5 slots in each end on the flap he worked on, and I cut about 10 slots in mine.  Turned out it didn't matter as both worked fine and we were both able to shape the fabric around the curved edge.

Fabric covering the end of the flap

We also did a 3 stage shrink of the fabric on the flaps, which is always satisfying because it tightens up like a drum and starts to look like a real part. 

We applied reinforcing tape over the ribs, burned through the tape and fabric at the rivet hole locations with a soldering iron, and installed the rib-stitching rivets.  These rivets just add a little more insurance to ensure the fabric will always stay in place.

Rivets installed in the ribs

Life isn't perfect, and I had one "oops" moment.  The rivets near the trailing edge were a little tricky because there was not much room beneath them due to the taper, so we pulled them with the manual puller.  On one of the rivets, the puller bounced on me when the shank popped, and the sharp end of the shank hit the fabric surface, making a small tear near the rivet head. So now I have a little spot where I need to make a patch.  Not a big deal, but these things happen.

Hours: 5

To be fixed: a small tear on left side of this rivet

More Fabric work on Flaps

We continued to cover the two flaps.  We added two inches of fabric overlap on the leading edge as required.  After applying three coats of adhesive the fabric was cut and attached to the leading edge.  The Just manual and the provided pictures show a good way to add the fabric endplates for the flaps and later the ailerons.  A fabric "flap" is left on the ends and is used to add the endplates.  Hours: 2

Fabric "flap" used to cover ends of the Flaps

Flaps getting Fabric

Started working on fabric covering of the flaps.  We started by cleaning the dust off the flaps.  After hanging around for a few months, a lot of dust had to be removed.  Once cleaned, we added three good coats of adhesive on the leading edge and ribs.  The manual specifically calls for adhesive NOT to be added to the trailing edge.  After allowing the adhesive to dry, the the fabric was placed on the flap frame.  Holes were added for the two hinges points and the pulley attach point.   The fabric was glued to the the the leading edge, fabric attach plates, and finally the ribs on the bottom side.  Hours: 5

Michael and Ed working on Flaps

Flaps getting Fabric