Completed preperation of the flap assembly - 3.5 hours

My shipment from Vans had arrived with a replacement flap spar, and replacement angle. I wasn't sure which piece I was going to remake/replace as I could do either, so I ordered both. Once I started down to business, I decided to give redoing the rear spar a try rather than cut a new angle bracket....again. First I removed the old spar and cleco'd in the new spar and match drilled the skins..again.

Everything looked good, so I fit up the attach brackets I had and match drilled the holes to the new rear spar. This time, it was perfect.  

Now, the next tricky operation is to back drill into the angle bracket using the holes in the spar/rib as a guide. Carefully I started a pilot hole by hand, and then completed the holes using a drill press to ensure a straight hole. 

 Next was a part that I was unsure about. I had to match drill the ribs that have already been match drilled to #30. I was really careful not to make an oblong hole as this scenario makes it possible.

Next I had countersunk the rear spar where the hinge was to be riveted eventually.

 All that was left to complete the preparation for assembly was to drill the nutplate assembly. I used a 1/4" drill bit to allow for the future bolt.

 I sacrificed a K1000-4 nutplate and ran a tap through it. Using an AN4 bolt and washers, I installed a nut plate onto the rib. I aligned it and drilled the first #40 hole in the drill press and installed a cleco. Then I drilled the other hole.



 All finished...well sort of.

I still need to counterskink for the rivets, of course the rib is too thin for a standard rivet so I will use an opps river there, however the thicker material on the other side of the hole will allow a standard flush rivet.