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NOTE: Each of the pictures on this page is a clickable thumbnail which will open up to a much larger image for detailed viewing. In some cases you will notice differences between the photos and your plans and parts. This is due to changes made during the building of the prototype. I've tried to make note of the changes but if I missed anything please assume that the plans are correct.

Adding the Flaps

Image 1

Image 1

1. Begin by marking out the inboard flaps on the top and bottom of the wing center section (blue lines) which includes a line 2 7/8 inches forward of the trailing edge and 3 9/32 inches outboard from the root. Draw a second set of lines parallel to the first (black lines) which are offset 1/4" and 3/16" respectively. (Image 1)



Image 2

Image 2

Image 3

Image 3



2. Lay the plywood gap seal FL15 in place against the blue lines on the top surface of the wing and mark around it as shown in Images 2 & 3.







Image 5

Image 5

Image 4

Image 4

3. Carefully remove the wing sheeting between the lines on the top surface as shown in Image 4 and on the bottom surface as shown in Image 5. A sharp hobby knife or scalpal makes quick work of the task. Leave the line as we will clean up the openings later with a sanding block.

Image 6

Image 6



4. Use a razor saw or similar to cut through the ribs and seperate the flap section from the wing. (Image 6) Set aside the flap for now as we will finish the wing first and then fit the flaps.



Image 7

Image 7



5. Use a sanding block to clean up the edges and open them up to your lines. (Image 7)



Image 8

Image 8

Image 9

Image 9



6. Follow the steps shown in Image 8 to attach the 1/4" balsa FL5 trailing edge cap. Image 9 shows FL5 in place but PRIOR to lowering it 1/32" to allow for FL15.

Image 10

Image 10





7. Trace the root end of the flap cut out on to a scrap piece of 3/32" balsa as shown in Image 10. Do not glue in place at this time.



Image 11

Image 11



8. Glue FL15 in place along the top edge of FL5 as shown in Image 11. Leave the root end of FL15 loose as can be seen in the picture.



Image 12

Image 12




9. Cut out the 3/32" balsa end cap that you traced in Step 7, leaving it slightly oversize. Fit it into place and relieve it along its top edge to allow for FL15. It should fit up tight against FL15 so as to provide strength and support. Glue in place when satisfied with the fit and finish sand it to match the wing. (Image 12)



Image 13

Image 13



10. Mark a line extending the edges of the "pyramid" on the underside of FL15 as shown in Image 13.



Image 14

Image 14




11. Glue FL19 in place using FL17 as a guide to make sure it is vertical. Trim FL17 as necessary to match up to the mark made in the previous step and glue it in place as well. Note that FL17 has yet to be trimmed in the picture. (Image 13)



Image 15

Image 15



12. Install FL18 as shown in Image 15. It may help to bevel the edges of FL18 in order to get a tight fit.



Image 16

Image 16




13. Add the FL9 & FL10 stiffening ribs to the underside of FL15. It may be necessary to sand these slightly to prevent them from distorting FL15 which should maintain the line of the top wing sheeting. (Image 16)



Image 17

Image 17



14. Now we return to the construction of the flap itself. Start by cutting the flap into two sections at the outboard line you drew way back in Step 2. (Image 17) The cut-off will be added to the outboard flap later so stash it away in a safe place.



Image 18

Image 18




15. Trim the top sheeting of the flap to the inboard line created in Step 2 as shown in Image 18.



Image 19

Image 19




16. Add the 1/4" balsa leading edge FL7. (Image 19)



Image 20

Image 20




17. Sand the flap leading edge to shape using the detail drawing on Sheet 2 of the plans as a guide. (Image 20)



Image 21

Image 21




18. Bevel the outboard end of the flap section as shown in Image 21. This end of the flap butts up to FL18 and the angles should match when completed. Test fit the flap section to the wing regularly to check progress and work slowly until a satisfactory fit is achieved.



Image 22

Image 22




19. Using some scrap 3/32" balsa, cap the end of the flap section as shown in Image 22.








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