How to press fit bushing into W925A Flap Hinge Bracket?

[KazooRV-9A]

Well that's all water under the bridge,, I didn't see any notes in the 8-1/2X11 instructions that said to fit these bushings before installing the brackets. Unless I missed it... not impossible. And I just thought they'd interfere with sliding the skins on. I suppose I could have drilled and reamed the holes in line on a drill press beforehand, but just didn't think that far ahead. (Why did Van's drill the holes 1/16" smaller than the final intended bushing dia),,
Apparently I'm not alone.

And if reamers only open up the last thousandth's or so, it would seem like it would take more than a few reamers to get from .064" dia smaller than the final size. I don't see this as a feasible plan. Correct?

terrye, does your approach take 6 stepped shafts, because you'd drill out the smaller snug fit end in the bracket each time?

Will progressively drilling them by hand in small size steps, up to where they can be final reamed, really wander too far from a centerline alignment that will work with the flaps? The flaps are pretty long.

[terrye]

Originally Posted by KazooRV-9A

terrye, does your approach take 6 stepped shafts, because you'd drill out the smaller snug fit end in the bracket each time?

No. One stepped shaft to align the plate, then push the stepped shaft out thru the plate to reuse on the next hole, leaving the plate clamped to the flap bracket.

I just measured my flap brackets and they are just undersize from 0.375" (I primered them). Maybe Vans missed a step on yours?

[N941WR]

After reaming the hole to final size, I used a C-clamp to press the bushings in place.
Note the duct tape to protect the aluminum and brass.


(Click to enlarge)

[danny]

Sounds like the holes in the hinges are not consistent in size. I used a couple big washers and adjusted some vice grips to get the right fit.
danny

[KazooRV-9A]

Ok terrye I finally understand your approach. I have a lathe also, will look into making such a guide.
I?ll gage pin all my brackets, see exactly what Van?s sent me. Seems to be some discrepancy in reported factory hole size...

[ClayR_9A]

I built my wing 14 years ago, so I likely forgot exactly what I did, but I think you're overthinking this.

When you rivet on the brackets, the idea is you use string to make sure the existing holes line up as best you can. Then, just ream the holes so you can press fit the bushings.

The alignment of the 3 holes isn't THAT critical, I don't think. You'd have to really have them out of alignment to cause any kind of binding or issue with the flap movement.

A quick phone call to Vans will confirm. Comment here if I'm wrong.

[terrye]

I just measured all 6 of my flap pivot bushings and they are all 0.376" OD. This should provide an interference fit on a 0.375" reamed hole.

[eric.the.blonde]

I think Clay is on to something. Surely these three bushings will have a different alignment when the wing is generating lift vs mounted on a rig in the shop vs parked on the ramp. The design must have some slop to account for the wing's natural flexing. I was looking forward to riveting on my brackets today before i saw this thread...

[toddramsey]

I?m also waiting for the answer.

[KazooRV-9A]

This was my Question to Van's Support:

Gentlemen,
I have a question on installing the .375" O.D. dia bushings in the W-925A flap brackets. This is an older kit (90072), and the as-supplied holes in the brackets I have, measure .311" dia. (The brackets have been installed and the skins are in place).
How do I get the bracket hole size to a press fit for the bushing? I posted this on the Van's website, and some (not all) other builders have posted that the holes in their brackets are at/near press fit sizing, while the ones I have are approx. 1/16" undersize, or much too small for a single reamer.
Given that the plans have required checking that there's close alignment of the 3 flap brackets, how do I best enlarge the holes to a size that will allow press fit? I did not attempt to install the bushings before installation of the skins, as they would have interfered, and when I went to do the bushing installs later, I found this issue.
Thank you,
Andy Cotyk

This was their Answer:

"They've always been undersize, but should be reamed here.
Hard to know, but probably years ago some escaped without reaming – that 's the perils of picking up used kits: 97002 doesn't have a wing allocated so someone must have picked up a used kit somewhere to go with the other kits.
All that said, at this point you're going to have to find a way to ream them to .374 – replacing the brackets isn't feasible now.
Good luck,
vans"

1. This was a wing kit that came with my build (is #90072, not #97002..)
2. I don't see what it matters, that I took over a kit from another builder that passed away. I mean, the real "Peril" here, was that the brackets were manufactured at a diameter much too small to final ream to fit the supplied bushing. I don't appear to be the only builder asking how to do this.
3. "I'M going to have to find a way to ream them". No guidance from the Manufacturer...?
4. I usually get far better assistance from Van's support, I am surprised at this response.

In the end, I plan to make a drill guide as terrye described in this thread. I'll drill accurately/aligned to a size that can be final reamed. I'll post pictures of it when I get it made. This would seem to be kinda important, don't want to foul this up considering how hard it would be to replace a bracket!

A.