Flaps
You are obviously operating a -4 with manual flaps. When I built my first -4, completed in 1988, I did go with manual flaps since the electric option was not yet available. I had a fairly early major incident, and when the aircraft was rebuilt, I retrofitted the aircraft with the electric option, which was then available. I flew my first -4 for 1,400 hours and then sold it, after completing another RV. I am now again back to a -4, with electric flaps.
The nominal cost of a conversion to electric flaps is worth every penny it will cost. I suggest you consider going this way, which will then take away the effort of extending them when you have a large air load at the top of the flap-speed range.
The conversion is not a big deal, since all areas are accessible. You can either convert your current weldment to an electric style, which would cost $425, or go with a replacement weldment and the total cost will be $550, based on current catalog prices.
JT
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