Here's a collection of pieces that had to be fabricated for the flap motor mount:
The flap channel gets fitted thusly. The plans call for the joint plate at the top to be bent to an angle of 151.8°. Yeah, whatever – we're not building the space shuttle here. I just adjusted the bend angle until everything fit and drilled it in place.
Here's a shot of the rear side of the flap channel, where the motor pivot bolt goes through. The angle bracket is a little crooked, but that's how the motor geometry worked out. I've seen this on other builders' sites so I don't think it's a problem.
The motor can run the flaps through the entire range of motion without binding or rubbing anywhere. This is up:
This is down:
I got the side panels mostly fitted before calling it a day. With everything in place the flap motor has a little house to live in. I still need to deburr the side panels.
On the left side, you have to notch the side panel to clear the pivot bolt head. I clamped a piece of scrap aluminum to the edge of the cover and used a unibit, which worked well.
