10 Oct 2026 - 4 hours

I got right into it by match-drilling the top skin of the right flap today.

Then, I fabricated the flap reinforcement brackets. These get cut out of a fairly beefy piece of aluminum angle, then the shorter side gets trimmed down to 3/4" tall. I did all these cuts on the band saw.

I cut on the waste side of the lines and then got them to final size with a file. Then I smoothed them on the scotch bright wheel and they looked great!

I carefully marked for the holes through these brackets and into the spar and drilled them out. I moved on to bending the other flap reinforcement piece to 6.3 degrees. This is a huge pain as they are thick pieces which don't bend readily and it's very fiddly getting them to fit to my satisfaction on the spar/aileron intersection.

I managed to take no pictures of this part, but once they were fabricated/bent, the pieces were applied to the flap spar and all the holes were drilled between the various parts. This was one of my least favorite parts of the build so far. I just found it frustrating and tedious.

Once everything was drilled, I started taking the flaps apart. I left the hinge attached to the spar and used it as pilot holes for countersinking the bottom flange of the flap spar. Next up on the todo list is to deburr all the remaining edges and holes and then prep for priming, priming, and riveting!