I got as far as I could on the fuel tank until I bite the bullet and order some polypropylene tubing from Van's to finish insulating the mounting screws for the capacitive fuel sender plates.  Sooo, I decided to break out the parts and start assembly on the flaps.

Of course, i spent about an hour looking for all the flap parts, removing the vinyl, and deburring everything.

The skeletal structure of the flaps is pretty straight forward and easy to cleco together.

I read about the ribs and shimming them to fit up against the rear spar....  Am I missing a part???  I don't remember seeing a spar in what's left of my wing crate.  You can see the "lone hole" for riveting the flap rib to the "rear spar".  The rear spar that the instructions are talking about is the lower flap skin is punched / formed to give it a curl on the trailing edge forming a spar, so to speak.  The lower flap skin is fairly stiff considering it is otherwise flat.

When Van's forms the ribs (mine at least), they were not all that close to the "rear spar" of the lower skin.  I used the offset seaming pliers to tweak the trailing edge flange.  I was able to get all the ribs VERY close and should eliminate the need to install any shims in this location.

Another spacer that Van's has you fabricate is for the outboard and inboard ribs (i.e.: FL-704-L  x2  for the left flap).  I just used some 0.020" scrap al-clad I had laying around and duplicated the dimensions to the exposed rib you see.  NOTE:  The plans tell you to make this spacer out of 0.025" 2024-T3 Alclad.  I used a caliper and the bottom flap skin measured out at 0.020" so I used the same material for the spacer.  Your mileage may vary. :^)

On one of my flap spacers, I positioned and cleco clamped the spacer to the underside of the rib and then drilled the two holes.  This made it easier to cleco the rib, spacer, and top skin together with just the standard cleco's to get everything match drilled.  On the other side clecoed the "blank spacer" when installed the top skin.  I found this a lot hard to get everything lined up and clecoed.

After fabricating the two spacers and getting the bottom skin clecoed on, I positioned and clecoed the top skin on.  It worked best to position and cleco clamp my spacers on before I clecoed the rest of the top skin on.

Within an hour or so of actual working, the thing was starting to look like another aircraft control surface. 

Drill, Drill, Move Cleco's, Drill some more.

The next fabrication activity was to make a reinforcement angle out of some AA6-125x1 1/2" x 2".  Van's instructions were pretty good for this as all the dimensions were listed on the print.

I only drilled the 5 holes that do not attach the angle through the rib or the FL-706B.  I will drill those additional 6 holes when I fit the angle to the flap spar.

I repeated the angle drilling exercise for the right flap angle.  Since the 5 holes are symmetrically spaced from the edges, I just used my left flap angle and clecoed it to the back of the right flap angle and started drilling.  Took all of about 3 minutes to make the second flap angle.

Woo Hoo, I am starting to move on past the fuel tank.  Will I ever get to unpacking the fuselage kit?