SonexBuilders.net

All,
We are righing the flaps. I have two observations:
1) the top corner of the flap is a little proud of the wing skin. Is this common?
2) with the flap jammed against the TE of the wing skin I cannot get the 2 59/64" dimension as shown on detail N. It is larger. Do I have to file the TE of the skin?

I am starting to think I need to move the hinges a little higher on the flap. That would both make the top surface flush and give me more travel.

Hey Bryan,

It's been a while since I was there but I do remember being warned that the flap hinge half that's riveted to the aft spar has to be back enough so you get full up travel on the flap itself. If the hinge is too far forward, the top edge of the wing skin trailing edge will prevent the flap from going full 'up' travel.

I don't remember my flap being proud as compared to the top wing skin. Is this the hinge you offset by a yardstick's thickness when you fit it?

Mike,
That is the hinge and I believe I did offset it. Would be much easier to put a new hinge on the wing than on the flap. Perhaps with more travel it will not look proud. I'll have to look at the geometry.

The flap is about .040" proud on top and .025-.035" shy on the bottom. I am definitely redoing the hinge on the flap. The current situation is too much like a cracked spoiler to me. Meanwhile we have pulled the wings and will store them - onto the other 90%.

Just thinking out loud here Bryan. If the hinge loops on the spar have enough overhang? Maybe they could be tweaked down one loop at a time? 0.040" isn't much of an offset.
Steve
Sonex 892

Bryan Cotton wrote:The flap is about .040" proud on top and .025-.035" shy on the bottom. I am definitely redoing the hinge on the flap. The current situation is too much like a cracked spoiler to me. Meanwhile we have pulled the wings and will store them - onto the other 90%.

Hi Bryan,
I finished up my flaps and ailerons and finding I have the same situation with my flaps...the top surface of the flap is higher than the top of the wing skin by too much to ignore. I had the same thought, cracked brakes on a 103. I tried to offset the hinge by the spec .057 but I lost it somewhere. My flaps are completely finished and I'm concerned if I drill out the hinge rivets to move the hinge, I'll just ruin it. Were you completely riveted when you found your problem and how did you solve it?

The flaps look great, but they're not. I'm thinking I may have to do them over...

thanks,

Peter
SNB0021

Peter,
Check out the last post on page 82, and follow the topic to page 83.
viewtopic.php?f=39&t=578&start=810

Was not a hard fix. I would not redo the surfaces, copy my recovery instead.

Hello flap, aileron, elevator and rudder builders,
This is the way I installed hinges on the moving parts, use the hinge pin as a guide and lay it on top of the hinge-half you need to drill. The diameter of the hinge pin is the distance you need between the edge of the skin and the hinge-half.
This worked out well for my Onex and I am using it too for the Waiex-B. see pic.

Bryan Cotton wrote:Peter,
Check out the last post on page 82, and follow the topic to page 83.
http://www.sonexbuilders.net/viewtopic. ... &start=810

Was not a hard fix. I would not redo the surfaces, copy my recovery instead.

Thanks...that will work great once I figure out the distance and I'm a bit perplexed...
I was able to take some measurements today. The upper surface of my right flap is about an 1/8" above the wing surface. The measurement called out in the plans between the hinge loop and the bottom surface of the flap is .057. I was off by about .01 but still I have that 1/8". I'm missing something...even had I nailed the .057 I would still have a high surface.

The height of my flap at the hinge is 3 19/32 and the plans call for 3 17/32. But it is what it is meaning my skin is seated perfectly on the ribs and my rib flanges were square...my flaps are tight.

Btw if I were to do the hinge pin method mentioned in this thread it would make the issue worse...my hinge needs to be moved up on the flap to bring the top surface down....but an 1/8"? That would put the new hinge rivet hole very close to the loop.

So I'm not sure how far to move the hinge. The aileron and wing surface are dead on.

peter