Left Wing Gap Seals

The gap seals were cut to length to fit between hinges and then mitred at 45 degrees using a disk sander.

Next, holes were drilled every 8-9" while maintaining specified edge distances.  A dremel drum sander was used to notch areas where underlying bolt heads on TE spar were located which would have precluded seating of seal.

Using a 4' level, I struck a line corresponding to the top of hinge elevation.  The top of gap seal matched this line.

Two-way tape was used to adhere the gaps seals while transfer drilling was done into the TE spar.  Clecos were used to hold piece during drilling.

Following deburring of holes, I then riveted gap seals to trailing edge spars.  Next, using a block plane, I then trimmed trailing edge of gap seal to create a 0.06" air space between gap seal and flap/aileron.

Here a completion pics.

Hard to see, but bolt heads underlie the covering on the TE spar.  These areas were notched on the gap seal.

The mitred ends were constructed to facilitate potential bolt removal.  The rivet holes were located 1/4" from bottom of gap seal rather than along centerline so that the pop rivet gun head would fit unobstructed.

Gear Leg Reinforcement

I've been told that the existing gear leg shaft in fuselage socket connection is the achilles heel of my vintage plane design.  A hole is drilled and a single bolt extends through the socket and shaft.  Over time, repetitive landings on rough ground and especially with bigger tires tends to over-torque the gear shaft causing the softer socket metal hole to wallow out.  The factory has since corrected by welding steel reinforcement "patches" where the bolt goes through.  I decided to address this potential problem now and avoid headaches later, especially since I plan rough field landings with bush tires in the future.  Several guys had purchased steel shaft couplings for added reinforcement.  I wanted to avoid the extra weight and purchased aluminum two-piece collars with cap screws.  I could not find an assembly long enough, so I purchased two collars and had them welded together.  Here are the collars as-purchased.

Here is an installed 1-3/8" welded double collar installed over the gear leg socket.  The gear leg shaft is inside the socket.  A longer bolt now runs through the entire shaft, socket and collar.  I applied JB weld epoxy to the inside bearing surface of the collar before tightening down the 4 cap screws.   I also stripped all of the paint from the socket bearing surface, before installing the clamps.