flaperon hinges

[ken nougaret]

I don't think removing the hysol is easier in this case, because my butt ribs are already installed. removing 1/2" of aluminum sheet shouldn't be very difficult. but i'll wait till I talk to john.

[HighWing]

I am curious regarding John's advice, but now understanding the issue, I would suggest using a dremel with a cut off wheel for the cut. You can make the cut slightly over size and then sand or file. Using snips would, in my experience, make waves in the aluminum along the cut lines. You will also need some foam to close out the open end. If you will be using the Hysol to install the faom, craft store foam would work. All doable.

Then the other thought, is the #1 rib the only one affected by the alignment discrepency?

[Geowitz]

I believe the metal end rib that is riveted to the flaperon skin(that the spar and control horn shaft pass through) would actually close this out, correct?

Sounds like a slight trim of the flaperon would be easiest and unnoticeable to even the typical Kitfox builder as all other measurements would remain the same with the control horns.

[ken nougaret]

to let you all know john's solution; he is sending me 2 flaperon hinges that have the tab welded all the way to one side. if this doesn't make up the whole 1/2" then I will cut off a portion of the flaperon end rib where the spar passes through. sounds good to me.
ken

[SkyPirate]

The hinge mod sounds like the better idea, if you ever sold your plane down the road, not sating you would, but if you did, and the buyer smacked up a flaperon it would be just a replacement, not a replacement and a mod to make it work