Today I got started on fitting the flaperon brackets to the wings, and right away I ran into a problem. As you can see in the photo below, the bend in the right-hand bracket isn't properly aligned with the axis of the bracket, so the flange that mounts to the cap strip isn't straight. With the two brackets parallel to one another (notice the second -10 washer), this causes the rivet holes to be misaligned, putting a couple of the holes at the forward end of the bracket half off of the cap strip.
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Even if I don't make the brackets parallel (by removing the washer), there still isn't adequate edge margin. There's no hole for the washer anyway, so I presume you're not meant to mount the brackets parallel.
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Many of my brackets either have the bend in the wrong place, or have another problem. At the forward end of the bend, a bit of steel sticks out to the side, which prevents the brackets from sitting flush against one another, again leaving inadequate edge margin.
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Has anyone else found these problems, and figured out a solution?
My only thought on this is to grind away the protruding bits of steel at the forward end of each bracket, then drill new rivet holes that will provide better edge margin on the cap strips and the underlying reinforcement brackets. But, that'll look pretty bad. And, it won't salvage the right-hand bracket in that first photo.