Installing the Flap Actuator Weldment - 5.5 hours

 I'm ready to fit the WD-613-EF flap actuator weldment. In order to start I need to drill the F-680 flap bearing block according to the plans. I made a drilling template to help start the holes in the correct spot. I used a palm drill to start a hole and finish the holes on the drill press.

Next I need to trim the block down on one end.

The bearing block is ready to cut in half. Using a piece of oak as a band saw guide I am ready to cut.

The instructions have you open the clevis ends of the flap weldment to 1/4". I used drills to open up the holes with the final step using a 1/4" reamer. I'm really happy with one of the clevis ends, but the two outside clevis ends, the holes are a bit loose for my liking. It has everything to do with I used a palm drill to do the holes and not a drill press. I will order a new one and do it right. (bit of an expensive mistake). 

 Fitting the WD-613-EF flap actuator weldment in the airplane is a head scratch-er. In the end you have to fit one bearing block on one end. Turn it 180deg so the shortest side is pointing up. (see pic below)

Fit the weldment into the plane and then you will just be able to slip the other bearing block on the end. Turn the bearing block so the short side is pointing down (see pic below)

In this configuration, the weldment assembly is at its shortest dimension allowing it to slip into the plan. The bearing blocks are then rotated into their proper orientation and then can be bolted in place.

 I need to notch the forward edge of the F-680 bearing block. Using the band saw and going slow does a decent job.

The bearing block can now be fit and once the final location is set, I used a drillbit to dill an initial hole for the mounting bolts.

Finish the holes with the palm drill and a reamer...good to go. 

I am ready to start fitting the nutplates.