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I thought about the flap brace some more. Reading through the RV-7 Yahoo archives, the best approach is to dimple the bottom skin, countersink the flap brace, and just drill the flap hinge. This is the sequence I’ll try:
1. Prime the flap brace and rivet it to the rear spar. Also install the aileron gap seal and brackets.
2. Install the aileron.
3. Cleco on the bottom skins.
4. Align the flap with the aileron and drill the bottom skin to the flap brace to the flap hinge.
5. Remove the bottom skins, dimple the holes along the trailing edge that connect to the flap brace.
6. Countersink the flap brace (with the bottom skins off, this will be easy).
7. Rivet on the bottom skins including the skin to flap brace to flap hinge.
Now that I’ve thought about it for a minute, it seems easy. Getting the sequence right is half the battle.
While searching the archives, I answered two other questions. There are two methods of handling the flap hinge pin. Cutting it into two parts and securing it in the middle seems to be the most popular option. The other question I had was about the flap hinge material that hangs off a little on the wing side. Dan just cut off the extra.