I ended yesterdays article with the following picture. As you can see, the flap skin is way too close to the fuselage skin.
There needs to be a gap here to allow safe travel for the flap. This is something you can't measure upfront and will only see the first time that you rig the flaps on.
I looked for a value in the manual but couldn't really find an indication how wide this gap should be.

I asked the question to Vans support and Gary answered that he removed a little material on his 7, but not more than a millimeter or so.

That still looked very little. I looked some further and found an artigle on vansairforce that discussed this issue. One guy said he had 1/16" gap before and had issues after a while with the skin of the fuselage being marred and damaged because of the flap touching the skin in flight. He said he enlarged the gap to 3/16" and never had any issues anymore later. So I went for the 3/16 gap.

While the flaps were installed, i measured the distance from the fuselage sik on the flap at various locations. Then connected the lined and got myself a cut line.

Then carefully file away the excess material with the vixen file and some key files. Test and install a couple of times to fine tune and then sande and edge deburr.

Same process on the other flap.