When I was installing the L-angle onto the back of the control horn I thought it odd that there was such an overlap above the control horn. I didn’t spend much time thinking about it other than I’d have to file it down later.
It is even easier to see here.
But what becomes real obvious from that picture is a problem with the control rod hole, you can see that it is obstructed by the skin behind, the rod is not going to fit uninhibited through that hole. Indeed, looking at the plans the horn really should be “up” more, level with the l-angle.
I quickly worked out what I had done wrong (too difficult to describe here) so I am confident I will get it right on the other inboard flaperon but it does mean I will have to drill this one out and replace it. I am hopeful that I won’t need to drill out any rivets on the spar, just the ones that hold that rib in place. Hopefully I can then pull out the rib and install a new one. I sent my plight to the tech support line at Zenith and they seem to think I will be ok but we will see how it goes. I will wait until the other two flaperons are finished before I do it (I may have to order more replacement parts!).