During the pre-buy on my RV8 we noticed the flap actuator rods were bent for clearance. I figured I'd just correct the issue later.
Today I'm installing the PH Flap Motor and decided to put the straight rods in while I'm at it. I now see why they were bent, the angle a straight arm needs to follow is nowhere near where it needs to be. It's much worse on the left side.
Opening up the through-hole is not an option as I'd need to cut up higher into the fuselage side, and I'm already at the max without cutting into the flap stop.
These photos show the issue:
So I see my options as:
#1 Leave the bent rods in, they've been working just fine for 380 hours
#2 Space the rod outboard down at the flap, but how far out could I go down there? I could also weld or modify the big white actuator that moves both flaps. I'm a very competent welder it would be no big deal to fab and weld new arms or spacers on the inboard side of the existing arms, but then how much will the arm protrude into the cockpit with the new angle?
Next question, specifically regarding the PH Flap Actuator. How much play should there be in the whole system? The builder left all the rod ends with no spacers so they could float back and forth along the bolts holding them to the actuator arm. Same with the motor to arm connection. If I slide washers in there to remove all the side-play, I get a lot of drag on the whole system which I'm sure isn't good for the motor.
Also, should I rig the flaps to pull tight right up against the stops on the fuse, or leave a small amount of play in there? When you grab a retracted flap, should it have any slop in it at all?
Thanks in advance guys