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Zenith CruZer & Sonex Logs
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Date:  3-7-2018
Number of Hours:  2.10
Manual Reference:  C75-AA-1
Brief Description:  Build left inner flaperon skeleton

Cleco'd skeleton parts together for the left (and last) inner flaperon. Fabricated the hinge attach brackets out of extrusion stock.

When drilling the inboard attach bracket, I screwed up trying to save time. I started drilling right off the bat with the #20 bit instead of drilling pilot holes at #40, then updrilling to #30, and finishing off at #20. NOOOoooooo..... I have to try a shortcut. Anyway, the hole didn't line up just right, and drilling from the backside enlarged the spar hole as well, so I updrilled both the bracket and spar to #12 and fastened that one hole with an AN-3 bolt, nut, and washer. See pic 1.

Once that ...ummm.. upgrade was completed, I finished deburring all of the skeleton parts and riveted all together using lead shot bags to keep everything flat.

Lastly, dug out the last remaining flaperon skin and temporarily installed the skeleton. Still have to debur the skin, then rivet in place.
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Upsized hole with AN-3 machine screw

Upsized hole with AN-3 machine screw

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Completed left inner flaperon skeleton

Completed left inner flaperon skeleton

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Skin laid in place; still need debur

Skin laid in place; still need debur

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