RE: ZIROLI 98
Flap hinges.
Instead of using pin hinges at a 45 degree angle, I've decided to make new low profile hinges from G10. With the flap cut for the removable wings and also using 4 servos, I need a lot of accuracy to get all flaps functioning together. Centering the hinge pin (4/40 screw) exactly on the TE of the wing will give me the accuracy that I need. The hinges will be installed before removing the flaps from the wing to insure everything is exactly aligned. I didn't think I'd get the accuracy needed trying to drill holes at a 45 degree angle with a hand held drill for the pin hinges.
I cut some paper templates to insure my dimensions are correct and cut the needed hinges out of G10. The flap side gets 1/8" thick G10 and the wing side gets two 1/16" thick G10 with 1/8" thick aircraft ply sandwiched between the G10. 4/40 screw and locking nut secures the hinges and will make removing the flaps easy. I had to use my floor model band saw to cut the G10. The dremel cut off wheel also works and the oscillating sander smoothed out the edges.
I made a master copy and made all the others from the master set.
Three at a time were clamped to the master copy to drill the hinge pin hole. Five holes were also drilled in the base to give the epoxy some tooth.
I already installed the balsa block hard points for the flaps so I had to cut slots using a razor saw, xacto blade and an xacto saw blade. The saw blade worked the best to remove the waste after cutting the slot with the razor saw.
This, virtually, took all day to make the hinges and cut the blocks and epoxy all flap hinges in place.