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RV-7 Construction Log
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Date:  2-12-2013
Number of Hours:  2.20
Manual Reference:  p 7-11
Brief Description:  Left Flap

Since my last session in the shop, I studied VAF and several builders' logs on how to best locate the hinge on the flap. There seems to be two schools of thought: (1) Set the flap half of the hinge as far forward as possible while maintaining the minimum 3/16" edge distance to the aft edge. This maximizes the edge distance available on the wing half (at the expense of edge distance aft of the holes, it turns out). (2) Go with exactly the plans specified 1/4" edge distance on the flap half, align the flap on the wing after assembly, then mark the hole locations on the wing half. If you have the minimum edge distance there (some folks did, some didn't), go ahead and drill that hinge to the wing. If minimum edge distance is violated, you can buy one length of wider hinge with the same pitch and barrel size, and use each half of it on each wing.

One builder noticed that when he used 1/4" edge distance that the gaps between barrels lined up nicely on the edges of the spar and skin. I measured the hinge and the holes and found the hinge to be 1/2" across between the barrels, and the spar and skin holes to be centered 1/4" aft of the edges. So, using the 1/4" edge distance method, I didn't even have to mark a centerline on the hinge, I just lined up the hinge gap edges with the skin and spar edges and clamped it in place about every 6th gap to make sure it was straight (photo 1). I drilled from the center of the flap toward each end, making sure that the hinge was supported on both sides of each hole being drilled.

This worked quite well, as when I finished drilling, I reassembled the wing half of the hinge by lining up just a couple of barrels, and sliding the pin in. The wing side of the hinge self-aligned as I pushed in the pin, and the operation is smooth as silk, indicating a very straight hinge (photo 2).

I finished up by clecoing and drilling the top skin to the assembly. I did forget to insert the FL-708 shims before drilling, so I'll have to take care of that the first thing next session.
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Flap half of the hinge clamped so the gaps between the barrels exactly line up with the skin and spar.

Flap half of the hinge clamped so the gaps between the barrels exactly line up with the skin and spar.

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Hinge drilled to the flap, 100% clecoed, and reassembled.

Hinge drilled to the flap, 100% clecoed, and reassembled.

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Drilling of skins, spar and ribs is complete.

Drilling of skins, spar and ribs is complete.

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