Bill,

I had a similar problem with fitting the flaps on my Legacy.  My solution was to shim between the spar and each flap hinge fitting until I got the flaps to fit to my satisfaction.  Once set, I did a release with flox to provide a good mounting surface for the flap fittings.  Finally, I had to build out the bottom of the wing to fill the gap between the flap and the flap pocket.  It was a bit of work but necessary to get a good fit.

Jim Thomas
Legacy - Flying

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