Top Flite TOPA0415 - Manual (Page 41)

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7. Test fit the flap to the wing. The root end of
the flap should align with the wing and the tip end
should align with the aileron. There should also be
1/32" to 1/16" gap between the top of the flap and
the ply/balsa wing sheeting. Sand and shape the flap
as necessary to achieve this fit.
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8. Sand the ends of the flap for adequate
spacing between the wing and the aileron.
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9. Return to the first step and assemble the left
flap the same way.
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10. Use a straightedge and a ballpoint pen to
lightly mark centerlines on the bottom of the flap and
the bottom of the wing at the location of each hinge.
Note that the centerlines are perpendicular to the
flap LE and the inner TE spar.
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11. Glue together both pieces of the die-cut 1/8"
plywood flap hinge drill jig. As you can see in the
following photos, the drill jig will be used to guide
your drill for drilling the holes for the flap hinges. For
additional accuracy, glue a 7/32" O.D. (3/32" I.D.)
brass tube and a 1/8" balsa 90-degree gusset to the
jig as shown.
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12. Position the flap hinge drill jig on the bottom of
the wing, centering the brass tube over one of the
hinge centerlines you marked. Push the drill jig
forward until the tab on the bottom is contacting the
inner TE spar. Use a 3/16" brass tube sharpened at
the end or a 3/16" drill bit to drill the hole for the hinge.
Drill the remaining holes in the wing the same way.
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13. Turn the wing around so the LE is facing you.
Reposition the drill jig as shown and drill the holes in
the flaps. Just the same as when drilling the holes in
the wing, be certain the tab on the bottom of the drill
jig is contacting the inner TE. As you can see in the
photo, we’ve wrapped a piece of tape around the
brass tube so the holes drilled in the flap will only be
1-1/8" deep. The outermost hole in the flap should
only be 7/8" deep.
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14. Test fit the flaps to the wing with the hinges.
The outermost hinge in each flap must be shortened.
Move the flaps up and down and observe any points
of interference. Make adjustments where necessary.
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