Flap and Aileron Skins and Construction

Hello Team,

Apologies if this is teaching you to suck eggs, but I have seen too many people destroy good pre-formed Skins in the process of drilling and then riveting the skins up, resulting in twisted and buckled Flaps and Ailerons.

The Flight Controls and Flaps are Tapered with a rib profile that changes shape as well as size in Chord… this means the Ribs and Skins cannot be laid flat on a datum surface. If you do, one side will be flat, and the other will buckle as it tries to pull the ribs back into alignment.

To achieve straight Flaps and Ailerons, the centreline of the Leading Edge must align with the Trailing Edge. This can be done by wrapping the Skins around the Leading Edge of the ribs, then laying the leading edge on Hinge Blocks noting the height to the Centreline, then getting a long block of wood the same thickness as the distance to the LE Centreline to lay the Trailing edge skin tip on. This will ensure the Skins stay aligned and smooth on both sides of the ribs. They can then be drilled and pinned onto the ribs, then once finished, bonded with Proseal, and riveted together for a wrinkle free smooth finish.