RE: Building the JMP Firebird
Ok, so onto the next step, I had very little time today as I had to airbrush and clear coat a Harley, but in between Kandy coats and clear I got the flaps installed on the Firebird.
I did deviate a little from the instructions here to a method I've used in the past that is bullet proof.
In the instructions you are told to cut slots for the hinges in the flaps and the flap pocket. I was able to easily cut the slots into the flaps themselves, but the pockets were tough. I didn't have the right cutter to get the slot deep enough for the hinges so I used a slightly different method, I have no fear in this method, it is at least as secure as the one in the instructions.
Picture 1.
First I put 3 layers of tape on the inboard root of the flap, as well as along the lip on the back of the flap. I also put tape along the LE of the flap to guide me for the slots. The reason for the 3 layers of tape is to leave a nice even gap all around and leave room for paint so that things don't end up to tight after painting.
Picture 2.
The I cut the slots 1/32" away from the lower flap skin with a dremel cut off wheel.
Unfortunately my phone battery died (yes, camera phone, I know, it sucks) so while I waited for it to charge I got a couple of other steps done.
Step 1.
I transfered the hinge locations to the fuse along the flap pocket. I tried cutting the slots again with the dremel, but with the large support blocks in the fuse I couldn't get the slots deep enough to put the hinges into. So I went on to method 2.
Step 2.
Once I had the hinge locations transfered, and drawn on the skin the correct size, I routed the lower skin away where the hinges needed to go. I went the thickness of the hinge plus 1/32" deep so the slot lined up with the flap.
Step 3.
I then glued the hinges into the flap hinge pocket I created. Once that glue had set, I drilled a hole through the hinge, I then put a small screw through the hinge into the wooden block that is already installed in the fuse.
Picture 3.
This picture shows the hinges glued into the flap pocket, filled over the top with the same Everglass milled fiberglass I used for the inlets and sanded out again. I don't care how hard you pull those hinges, they are not coming out without destroying the fuse.
Picture 4 and 5.
Here are the flaps now slid back onto the hinges. I will glue them after I paint the inside of the flaps and flap pockets. I'm going to paint the inside of those now, then mask them off to paint the rest of the airplane. This way I can still easily glue the flaps on, pin the hinges, and fill, sand and prime everything plus have a perfect paint finish inside the flaps.
Picture 6.
Here are the flaps from behind, drooped down a bit from gravity.
Flap Linkages and horns will be next, then I'll paint the inside of the flaps and glue them on.