RV-6A Flap Handle Issue

[Will Bentley]

I'm presently having a problem with my manual flap handle button. I have checked the archives and haven't found anyone having this problem. While
on the ground and under no flap tension, my manual flaps perform flawlessly.
On approach, however, I find that about 50 percent of the time the button
is nearly impossible to depress in order to lift the flap handle. Also, I have found that "jiggling" the handle will often-times allow the button to "pop-out" which allows me to lift the handle and apply one or two notches of flaps.

After some research I can pretty well deduce that one of the dowels inside the handle is fouling where it engages the spring. Okay, so it seems that I could probably just order a new spring, button and new dowels and the problem would be resolved. So far I have had no luck locating the inner workings of the flap handle. Also, I'm not all that sure that my deduction is correct. Has anyone had intermittent (or constant) problems with their flap handle failing to engage the notched flap anchor plate?

I might add that the only time it has actually been a real problem is when I was needing to make an emergency go-round and I couldn't get the push button to depress in order to release the 40 degs of flaps I had in. Since, of course, I am here to tell the story, I did manage to keep worrying the button until it finally depressed and disengaged from the notched plate. I don't mind telling you, however, that the situation did make me flash to past experiences as to just how well this bird wanted to fly around the pattern w/full flaps. Not a true emergency, but it certainly isn't the way we'd like to fly a go-round under emergent circumstances.

Thanks RVers...

Will (Bill) Bentley, CFI A-I, ME...yadda-yadda

450 wonderful hrs on this flying RV6A

(you around, Vic?? Mel??)

[gasman]

On the ground, try the flaps and see if all is working well. The button should go in with pressure from your thumb, and should come back out without any problems. If is sticks, then pull it out and see what is binding. There is only a spring and a piece of dowell down in there.

If that works fine, then look at the slots cut in the guide. The slots must be wide enough for the bolt to slide in and out without binding. The ends of the slots should be rounded and not have any hooks on the end.

The last thing to look at....... is the bolt being pushed all of the way out of the slot with the button. If the guide flexes and the bolt does not clear the slot, then you can't bring the flaps down. My flaps were a big problem, just like yours. I shortened the handle and made a new guide and changed a few things, now I push the button and pull in the first notch. After that, the second notch I just pull for the next notch. I don't need to push the button. It is easy with little effort.

I LOVE MY MANUAL FLAPS.....................

[Will Bentley]

Yep, works perfectly on the ground. The minute, however, that
pressure from the wind is applied while flying the button begins
sticking. I suppose I'll just pull everything out of the tube and
attempt to see what's causing the binding. Strange thing is
that it worked perfectly for the first 350 hrs..then all of a sudden
became a problem.

I haven't seen anything that shows how to remove the button in order
to slide out the dowel & spring...I suppose it unscrews.

Sure sounds like you got yours working terrifically! Wish me luck...

Bill

[Mel]

Well. I don't know what to tell you. After 16 years I've never had a problem . I can tell you that the "pre-load" on the flaps is opposite in the air vs. on the ground. On the ground you have to apply down pressure on the handle to push the button and in the air you must apply up pressure, but I'm sure you already know this as it's the way with all manual flaps.
I would suggest disassembling the handle and take a look at everything. Whatever is causing the problem should be obvious.

[Will Bentley]

Thanks Mel...

Well, I did, indeed, spend the day at the airport attempting to resolve this issue. I disassembled the contents of the tube. Hmmmm, nothing obvious.
I tried various things. I'm beginning to think there is some binding taking place. I can feel it binding but of course can't see inside the tube to determine just where the binding is taking place. Could be the thin, metal piece that holds the small bolt (that engages the notch) has bent slightly. I also noticed a slight bit of play where that same piece is rivited onto the metal bar/button. I suppose that slight wiggling movement could make it bind. Guess I'll just stay after it. After doing a few mods, I decided to take the plane for a few t & go's to see if anything I did was effective. Wouldn't ya just know...the winds cranked up to 20-25 with a direct x-wind. I decided to hold off and fly on a less windy day.

Oh, on pushing the flap bar down to lower the flaps...and pulling it
up to raise them...yep, I'm aware. When this things sticks, tho, hardly anything will make that button disengage. Once, I actually had to pry
the button out with a screw driver while wiggling the bar in order to get
the button to pop out.

Think I'll buzz the guy's at Van's and see if they've heard of anything
like this...

See you...

Bill

[Will Bentley]

To Anyone That May Encounter This Sometime Down The Road...

In disassembling the contents of the flap handle I noticed the problem that has been causing my flap actuator button to stick.

Attached to the button is an aluminum rod - attached to this rod is a piece
of folded over aluminum that was riveted to the aluminum rod. The rivets had become loose allowing movement of this folded over aluminum piece. The movement caused binding of this assembly which caused the button to stick and often times stuck so hard that the flaps could not be retracted.

The fix: I replaced the rivits with screws, lock washers and nuts. The assembly is now solid. After a couple of test flights in the pattern I found that the flap actuator now operates as smoothly as silk.

Thanks to all for your guidance and attempts to help me resolve the matter.

My Best..

Will(Bill) Bentley

[Mel]

Thanks for posting the problem. Now we all know where to look if it happens to us.