Easiest Steps in the Build

The easiest steps in the build are Page 18-02 Steps 1 and 2, which has us fabricate left and right flaperon actuation brackets from ⅛-inch aluminum angle, and four flaperon pivot brackets from AEX extrusion as shown in Figures 1 and 2.

What makes these so easy you ask?  They certainly don't look easy.  It's because Vans went ahead and did the fabrication for me, so the parts are already done:

They did a nice job too.  Checking the builder blogs I read that some folks had a hard time fabricating these and had to reorder stock aluminum from Vans for a do-over.  At some point in the last year or two somebody at Vans finally said "You know what?  Builders are having a hard time with these.  We should just fabricate a bunch of these (or contract it out) and include 'em in the wing kit."  So there it is.  To all the early builders who were flummoxed while fabricating their own brackets, all I can say is BWAHAHA!  ; -)

Second runner-up for easiest steps in the build are Page 18-04 Steps 4, 5, 6 and 7, which has us match drill rivet holes in the A1206 pivot brackets and A1207 actuation bracket.  Again, Van's already did all the work (see picture above) and the holes matched up perfectly where they were supposed to go on the flaperon spar.  Love it when that happens.  The "second-runner up" status is owed to the fact that the instructions say to prime these parts before installing, which didn't take long.  I think it's because of the fact that steel rod-bearing bolts will be screwed in (or attached) to the brackets.  Unprotected steel in contact with unprotected aluminum = flow of electrons = eventual corrosion.  I went ahead and primed the entire flaperon spar, ribs, and stainless steel counterbalance as well, "just because".

Third runner-up for easiest steps in the build is Page 18-02 Step 3.  All I did is add some flutes at the prescribed locations on some flaperon counterbalance end brackets to flatten 'em out.  Here's a picture:

The flutes are added to flatten out the natural arch in the piece which comes from the factory stamping and forming process.


Here are before and after shots that show the arch being flattened after pinching a couple flutes to the work piece:

And here they all done, along with the fluting tool I borrowed from Mr. B:

So Page 18-02 took about 10 minutes and it was done.