Rear - Operational Wing Flap

Fletch

I wanted to get the flap to operate correctly before I mounted in the actuator. I followed Andy Bujtas examples on how to make a operational wing flap, except he made his flap part out of steel and I elected to re-form the existing fiber glass flap.
I started by taking the flap and making a template, to figure out how would this flap best operate and where the center point of the rod would be.
As I looked that this more I figured that the flap would work best if I turned it upside down. With this new idea to get the flap to fit against the bass, and I would need to cut the back section down at an angle.
I needed to cut the flap end section where the mounting screw was supposed to be mounted. With the flap being operational this will not be needed.

Here are some problems, the flap is not straight - you can see the light shining thru the bottom of the flap showing a 1/4" of bend where it needs to mate to the wing.
You can also see that flap before I filled in the mounting screws.
This is where I glassed in the mounting screws
Another after shot of a sanded part... this still needs work

Here is an end shot to watch the flap take shape. 
At this stage, I am going to start to weld my flap's inter-structure. I used Andy's advice and I took two 1/2" OD with a 3/8" ID weldable tubes, 3ft long. Put in a 5" long 3/8" rod in the middle connecting the two 1/2" OD rods and welded them all together.

 

I then welded on some 1/8" steel for the rod's flap support.

I needed to lay the rod into the flap. To cut a straight line into the flap, I used my table saw. I made two cuts (to the outside of where the rod would go.
I used the Dremel tool to round out the end points, and it is now ready for the steel flap support.

I notched cut out the fiber glass and lay this rod and support bars inside the flab (and then I will glass them in).

I then welded in this center flap push-pull lever to the tubing and in this photo you can see it located in the fiber glass flap. The other parts on the table will be attached to this lever.

My daughter Samantha (13) wanted to help me, so I gave here the Dremel and had her clean up my welds around the center lever.

The flap mounting pin - I cut out a slot in the rod and I took a piece of 3/8" stainless steel rod and tapped in a 10-24

This pin operates like a gate latch, I can push the pin out for normal operations. Lock it down (in the notch).

I can pull the pin back to remove the flap, this will need to be done to paint the flap.

Before fiber glassing in the steel rod I put a few coats of primer on it.

The flap is now ready for a few layers of fiberglass.

The fiberglass has been laid.

Next step - Sanding

 
Someone asked me to show how I cut my fiber glass, I buy my glass from TAP plastic (good price). I take the tube and draw a line and cut it... no big deal. 

 

If you ever wanted to see a close up of an air pocket, here it is. My car and ALL the fiber glass parts that came from CRP are full of these. The gel coat is there but there is no fiber glass behind it.

From the outside it appears to be alright, but you need to find and fix these before you paint your car otherwise they will crack and pop out later.

 
This entire Website is copyright © 2002-2007 by Ron Fletcher. All rights reserved.
Although my information comes from various builders and sources, if you want any information contact me. The photographs used on this site are used with permission, if you want to use any, contact them through the various links on this site. I did and you can see the results!