Doubler Overhang
I have the 1" overhang on my 6A WW doubler.
One day (after about 50 hours of flying) the flaps (electric) bound-up and released with a bang during retraction.
My guess is the pilot (me) stepped on the wing skin aft of the rear spar and bent the doubler down. The doubler caught on the rolled leading edge of the flap during retraction and folded the doubler forward over 120 degrees. This probably wouldn't have happened with manual flaps, but with electric flaps, and the big fan up front running, I didn't notice the additional effort required to retract the flaps
The only solution I could come up with was to cut the damaged doubler off about 1/8" aft of the rear spar with a dremmel cut-off tool and clean-up the new aft edge.
I'm not the first to have this problem. Since the doubler isn't riveted to the top skin aft of the rear spar the 1" overhang is a problem waiting to happen.
I have a couple ideas to prevent the dreaded 1" overhang flap-snag if your wing is already finished.
1). CUT IT OFF! Using a 1" dremmel cut-off disk. Slide a very thin piece of stainless between the two pieces and carefully cut that sucker off before it causes you problems.
2). Carefully spread them open a little, scotchbrite and solvent clean, then apply a very thin layer of tank sealant and clamp them together until the sealant cures. Use care and make sure you don't distort the top skin and mess-up the airfoil. This is just and idea and I haven't tried it, so you are experimenting with this one!
Good luck,