Flap 2

Once you get ready to begin riveting the structure together, you will want to made a cradle.  It is simply cut out of mdf and nailed to the bench about 42" apart.

It is extremely difficult to rivet the row of rivets along the rear spar.  Probably the most difficult riveting to date, as there is no access.  To make this process manageable, I ground a flat surface on one of my smaller bucking bars.  I then made a spacer that rested on the spar such that the flat surface on the bar would be the same height as the rivet line.  Not easy, but it worked okay.

Once you rivet things together, you will note that the tip rib rivets are impossible to buck.  It also becomes obvious that the rivet under the attach nutplate cannot be bucked either.  You can see the three MK319 blinds in the photo below.

Next step that is not entirely clear is when it comes time to rivet the end ribs.  You must be sure to install the pops in the ribs before you install the 470s in the side, as you won't be able to access the pops if you do the 470s first.

The last step in riveting together the structure is riveting on the hinge.  To install the hinge pin, you can either a) drill a hole in the aileron bracket, or b) remove three hinge eyelets and split the pin into two lengths.  I went with option b), as I thought it would be easier to install two shorter pieces.

Once the hinge is riveted on, you're done.  Everything is then repeated for the 2nd aileron.