Brian,
You can never go wrong with 6061-T6 1/8 inch sheet.
The advice given is quite good.
1. Be sure to make the flap fit on the left and right absolutely identical in
gap between flap LE and closeout, dead level with the bottom of the wing. Make
the line through the inboard and outboard flap eyes even and at the right point
using the template. Middle flap bracket is set with string. IF THE FLAP
W19 OR 20 IS TOO SHORT: Lay out your template and assure the wing flap is
positioned
per the manual using the incidence board and dead level with the bottom
of the wing then clamp your W19/20 brackets. If too short, simply draw out a
new one out of carboard for the outer shape and make another out of 1/8 6061-T6
After fab is complete, clamp in place and check operation. If off laterally
due to a FL1 or 2 misalignment , you may either bend the W19/20 or use a spacer
to displace the bracket to allow smooth operation.
2. I don't set my flap pins exactly like the manual. I use a compass (actually
a 3/4 inch thick stick and pin/pen). Each flap drive pin needs to be set the
same. I find that the swing of the flap tube and hinges is slightly off as
indicated in the manual and by using a large "compass" I can set each flap pin
so it is exactly in line with the hinges. It is not a big deal, but for those
of you always having to lift or pull down on a flap to get the flap engaged
with the wing pins in alignment, that is your problem or at least part of it.
I've attached a picture for my shop technique on the compass concept.
Best Regards,
Bud Yerly
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