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When I woke up today, I couldn't help but worry about the flap having a twist. It seems that none of the workbenches in my garage are 100% flat, so I turned to the kitchen. My counter is about as level as they come. I put the flap on it and there was about a 5/32" twist...doh. Now, I know there are a lot of RV's out there with worse, but I couldn't help but to try to make it better. No matter what I did, nothing did it with the bottom row of rivets set. So I made the executive decision to drill out all 50 rivets.  Now I put the flap back on the kitchen counter Without the spar being clecoed, I was able to get it completely level. When I put the top row of clecos in everything stayed straight. When I put the bottom row in (with hinge) things always went south. Mike was getting frustrated!  Knowing that the twist seemed to be completely independent of how the top row of rivets on the spar. With the hinge clecoed onto the spar, there would be a lot more interference for bucking the top rivets than without it.  The top row was very easy to rivet with the wood jig thingy I made last night.  Now when I clecoed the hinge to the skin and spar, things twisted a little - not as much. So I started riveting from the center outward. In the end, things still twisted a little again - 3/32" this time across the length. It was a lot of work to get 1/16" less twist, but I am glad I did it.  To finish up the flaps, I riveted the inboard doubler rivets. 
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Last Modified: October 5, 2024 |