Pat,

Your story sounds so familiar I had to check and see if I wrote it.  I had that exact problem with my flaps and here are my lessons learned.

 

1 On each of your four flap track mounting locations,  measure and compare the location of the three bolt holes in each of the mounting pads that are bonded to the rear spar.    In my case, three of the mounts  had holes drilled in identical locations but  the fourth mount had its three holes drilled .1  (1/10) of an inch further aft of the rear spar than the other mounts.

 

2  My belief is that when the wings were in the fixture at the factory and the jig was installed to drill the holes for the flap tracks,  there must have been something in the jig which caused the three holes on this particular mount to be drilled 1/10 of an inch aft of the others.

 

3 One measure you may want to make is with a spring scale attached to the flap actuator rod and see how much effort it takes to actuate the flap.   Before the fix,  mine was at 40 lbs.  After the fix, it dropped to approx 16lbs. 

 

** Special note - Please profit from my mistakes and realize that when you redrill this mount, the position of the flap with respect to the trailing edge of the wing has now changed and the gap between your wing trailing edge and flap will have changed.  This will rear its ugly head when you sight down the top surface of the wing and check for parallel between the aileron gap and the flap gap. 

 

 

 

Take heart, This is one of many opportunities for you to excel.   you will get its fixed and it will work as smooth as advertised. 

 

Craig