April 12, 2008 ...  The Right Flap is complete. Now on to the Left Flap!

April 15, 2008 ...  I spent my entire shop time measuring and pre-drilling the holes in the left flap skin, and cut the slotted opening for the flap drive bracket. I made the compound cut (for the wing dihedral) and deburred the flap skin.

April 22, 2008 ...  I lined up the left flap ribs, then pre-drilled. I dimpled the flap skin and ribs for flush riveting, and carefully deburred everything. I also cut the left flap hinge to length,  pre-drilled all of the holes, and deburred.  My last task for the day was to lightly prime the inside of the flap skin with self-etching zinc chromate.

April 28, 2008 ...  I riveted my left flap together today! Now both flaps are complete!  I cleaned up both flaps and covered them with white contact paper, like I did with the tail pieces.

May 3, 2008 ...  Time to start the ailerons. Today I was able to get the aileron drive plates and ribs fit together, pre-drilled, deburred, up- drilled (including the 3/16 inch hole), deburred, and alodined.

May 4, 2008 ...  I was only able to squeeze in a couple hours in the shop today, so I riveted the aileron drive plates to the ribs. I wanted to cut the lead weights for the aileron counter-balances but noticed that the block of lead that the Sonex factory sent me had a slight warp in it. So I placed the lead block in my vise, between two pieces of smooth, flat , 3/4 inch plywood and cinched up the vise.  It straightened right up! I cut the lead weight and started dressing it with a file. Then came the big "OOPS!"  As I was preparing to make the second lead weight, I realized that I didn't center my diagonal cut quite well enough, which didn't leave enough material for the second counterweight. It looks like I will be ordering more lead from Sonex.