Top Flite TOPA0305 Part 1 User Manual

Page 34

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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

make sure you use the correct wing plan for the

flap you are working on.

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.

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

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.

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.

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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.

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