L
5. Cut a hole in the inner wing
TE
for the flap
horn at the location shown on the plan. The hole
should be
biased
toward the top of the wing.
6. Place the flap over the plan and mark the
location of the die-cut 1/16" ply
flap horn.
Fit but
do not glue the flap horn into the flap.
Note:
Each
flap has a different location for the flap horn
so
make sure you use the correct wing plan for the
flap you are working on.
7.
Cut the 5/8"
x 1-318"
x 18"
balsa
flap LE
into two pieces that fit on both sides of the flap
horn. Cut a 1/16" notch in the longer LE to
accommodate the flap horn. Glue the LE to the flap
so the top edge is flush with the top of the flap.
8.
Remove the flap horn.
Temporarily tack
glue
the short flap LE to the flap with
a few drops
of thick or medium CA. Sand the ends of the flap
LE
so they are even with the ends of the flap. Sand
the top and bottom of the flap LE flush with the top
and bottom of the flap.
9.
Cut the flap
root and tip end templates
from the plan. Glue them to the ends of the flap
with rubber cement or spray adhesive. Use the
templates as a guide to shape the flap LE with a
razor plane or a hobby carving knife followed by a
bar sander.
10. Drill a 1/16" hole through the punch mark
in the front of the flap horn for the clevis. Add a few
drops of thin CA to the hole. After the CA hardens
redrill the hole. Remove the flap LE you tack glued
on. Insert the flap horn into the flap and securely
glue it in place. Permanently glue the flap LE to
the flap.
- 3 3 -
11.
Assemble the die-cut 1/8" plywood
flap
hinge drill guides
by gluing the pieces together as
shown.
Optional:
Glue a piece of 7/32" brass
tubing (3/16" I.D.) to the hinge drill guides to guide
your drill even better.
---
12. Position the
wing
flap hinge drill guide on
the wing over each hinge block (you marked them
before you sheeted the bottom of the wing) and drill
3/16" holes for the Hinge Points.
Hint:
Instead of
using a drill bit, use a piece of 3/16" brass tube
sharpened at one end to drill holes with
clean edges.
13. Insert three #309 Robart Super Hinge
Points into the holes in the wing but do not glue
them in. Fit the flap to the wing and mark the
locations of the hinge points on the flap.