Build Tip for Canadians -The best time to drill the hinge for the flap/wing is to mount the completed and closed aileron to the wing with just the underside of the wing skin clecoed on. Make sure that you haven't dimpled the holes yet on the wing skin that attach the skin to the flap brace. Mounting the flap hinge should be much more easy and precise.
Build Tip - When setting the hinge on the flap, I had placed it according to the 1/4" dimension as noted on the plans. When installing the flap to the wing, there was not much hinge left to mount to the wing. I was just slightly better than the minimum edge distance indicated on the plans, but it could have been better. In retrospect, this 1/4" dimension I used when installing the hing on the flap should be modified so it places the holes closer to the outside edge of the hinge. If I ever build another plane. The dimension I would use is 7/32.
I had temporarily set the flap in place and used a 1/4" thick wood shim and placed it between the flap and aileron. This allowed me to mark the location and ensure the left/right placement of the hinge was correct. After reading the different blogs, I made certain that the flap and hinge was all the way outboard so it didn't interfere at the fuselage (the hinge has some left to right play in it, I made sure the maximum gap was 1/4"..and it's minimum gap was less.).
Once I established the first hole, clecoed it and checked alignment, I began to work my way inboard. Checking, re-clamping, drilling a hole, re-check. repeat process down the line.
I found that using the fan spacer helped immensely.
Admittedly this process actually took me a couple of weeks and I went through a number of hinges. I was not happy with some of my alignments and choose to try again, and again. I wanted it perfect, and frankly hinges were cheap to order from Aircraft Spruce... So why not get it perfect. And in the end I did.
