Great Planes Super Sportster 90/120 Kit - GPMA0214 - Manual (Page 16)

D 6. Using an Xacto knife, sharpen the inside of
one end of a 1/8" diameter brass tube and use
it to cut a groove in the leading edge of the
aileron to accept the torque rod. Cut this groove
a little larger at the beginning, to make room
for the torque rod bearing. Trial fit the aileron
onto the torque rod and cut or file as necessary
until it fits.
D 7. Lay the aileron on the plan and mark the
hinge locations on the aileron. Place the aileron
against the wing TE and transfer the marks
over to the wing.
NOTE: The large one-piece molded hinges supplied
in this kit are strong, easy to install, and provide a
good dampening effect to help prevent dangerous
control surface flutter. We recommend that you use
these hinges in your Super Sportster 90/120.
D 1. Holding the die-cut 1/8" plywood dowel
plate on the leading edge, in the exact center
of the wing, mark the dowel locations through
the dowel plate holes.
D 2. Remove the dowel plate and double check to
make sure the dowel locations are both the
same distance from the wing center joint.
D 8. Cut the hinge slots using a standard slotting
fork and slotting hook. Because the hinges are
wider than normal, you should use the follow-
ing procedure: When first inserting the slotting
fork, push it in only part-way along one side
of the hinge location, then push it in the full
depth along the other side of the hinge location,
finally, go back and complete the push in the
original position. Clean out the slot with the
slotting hook.
D 9. IMPORTANT! Condition or "break-in" the
hinges by folding them tightly back and forth
several times.
D 10. Sand the leading edge of the aileron to the
same "V" shape as shown on the wing rib detail
drawing.
D 11. Insert the hinges into the slots and trial fit
the ailerons in place on the wing. Do not glue
the hinges until after you have covered the
wing.
There should be no hinge gap!
INSTALL WING DOWELS (Do not glue)
D 3. It is important that you now drill the dowel
holes accurately! To insure accurately
positioned holes, begin by drilling small (1/8")
holes in the center of the marked locations.
Then gradually increase drill bit sizes until
you have finally drilled the holes to 5/16"
diameter. The final holes you drill must extend
4-7/8" into the wing to penetrate the front di-
hedral brace.
D 4. Sand one end of each wing dowel to a
rounded or pointed shape. This is the end that
will be inserted. Do not sand the other end at
this time.
D 5. Trial fit the dowels into the dowel holes, and
trial fit the dowel plate over the dowels. Do
not glue the dowels in place at this time.
LOWER FUSELAGE
ASSEMBLY
D 1. Lay one of the shaped 3/16" balsa fuselage
sides in place on the fuselage plan side view.
Note that the front of the fuse side extends
forward beyond the firewall location, and this
extra length is used if a 2-cycle engine will be
installed. If a 1.20 cu. in. 4-cycle engine will
be used, carefully cut off the front 3/8" of
the fuse sides, even with the front of F-1.
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