My manual flaps

cjensen · Post by **cjensen** » Tue Jul 10, 2007 11:38 pm

This thread will be the one I use to show all how hard

it will be to install manual flaps in an RV-7 (besides my website...).

I thought I was a couple steps away from starting the installation changes, but as it turns out, it starts today!

The center tunnel cover that comes/is fabricated with the fuselage kit, is for mating up against the electric flap weldment cover between the seats. I didn't realize this until today while daydreaming at work...

So, tonight, I set out to fabricate my own center tunnel cover. This one will be a one piece deal with several bends and angles to figure out.

The bad news is (to get it out of the way) that the cover I made tonight, has two cracks where I made bends (yes I drilled relief holes). This one is trash. I will make another, and it'll be out of thinner aluminum than what I used tonight.

I started with this...

And ended up with this...

But, like I said, it's trash due to the cracks. It's by no means structural, but it's bad form...

The shape is dictated by the elevator push-pull tube that slightly protrudes above the seat line.

So, I'll have more pics and progress of this little project/challenge I've created for myself soon!

svanarts · Post by **svanarts** » Wed Jul 11, 2007 12:29 am

Very cool. I'll be watching this closely as I'm not too fond of the electric flap motor Van uses. Though lots of people never seem to have trouble with them. Mine smoked and I just don't trust them. I'd like the options of a manual flap mechanism.

captain_john · Post by **captain_john** » Wed Jul 11, 2007 7:22 am

Chad, that is an excellent first effort at freestyle metal bending!

PK would be proud!

Looking forward to seeing your progress!

CJ

cjensen · Post by **cjensen** » Wed Jul 11, 2007 9:45 am

To give people an idea of just what I'm talking about, and what I'm doing, here are a couple of drawings illustrating the area in question.

This is the unedited plans drawing of the original tunnel cover and flap motor/weldment cover.

This is my edited version showing where my tunnel cover will go, and a manual flap handle drawn in.

Hopefully that makes it more clear...

Post by **Spike** » Wed Jul 11, 2007 12:58 pm

Thats not an easy shape to deal with. Are you using a brake to do it?

cjensen · Post by **cjensen** » Wed Jul 11, 2007 1:59 pm

You're not kidding! That was a bear, and I get to do it again!

No brake, just wood blocks, a mallet, and vise.

svanarts · Post by **svanarts** » Wed Jul 11, 2007 2:29 pm

cjensen wrote:You're not kidding! That was a bear, and I get to do it again!

No brake, just wood blocks, a mallet, and vise.

Well at least now you have a pattern to work from. You can pound the prototype out flat and use it to cut out the next one. Using thinner aluminum is a good idea too.

cjensen · Post by **cjensen** » Wed Jul 11, 2007 2:53 pm

I plan to at least try that Scott. I'm afraid it's going to crack even more, and ruin the shape. We'll see. If not, I have all the measurements written down (did that in case I had to make it again...).

cjensen · Post by **cjensen** » Wed Jul 11, 2007 11:01 pm

Well, I'm happy to say that the piece I made tonight puts last night's work to SHAME! The aluminum I used is from a Cessna 172R rudder that was removed because of hanger rash. It's super thin, and probably three times lighter than what I made last night. It's primed with epoxy primer (I can see now why you guys like the stuff...) on one side, and white exterior paint on the other (no primer though...

)

Here are the pics in order...

Whatdya think?

JohnR · Post by **JohnR** » Wed Jul 11, 2007 11:19 pm

Looks great Chad. I need to get these projects finished around here so I can get back to the airplane. Your getting way ahead of me!

RV7Factory · Post by **RV7Factory** » Thu Jul 12, 2007 12:23 am

JohnR wrote:Your getting way ahead of me!

John, don't even start that. Remember the day when I was ahead of both you and Chad!?!?!

Nice work Chad!!! Can't wait to see it in person.

Mark Browning · Post by **Mark Browning** » Thu Jul 12, 2007 9:15 am

Hey i started the same time as Jamie Painter and he is already a year + in front of me. i don't care how long it takes, because i know for a fact that when this Bird is ready to fly i will want another.

TomNativeNewYorker · Post by **TomNativeNewYorker** » Thu Jul 12, 2007 9:26 am

svanarts wrote: Well at least now you have a pattern to work from. You can pound the prototype out flat and use it to cut out the next one. Using thinner aluminum is a good idea too.

On occasion, I have had to make replacement parts for damaged items.

You can take an item such as this cover and cover it completely with masking tape. Trim off any excess tape overhanging and then you can mark on the tape any bend lines or hole locations you need. Carefully peel off the tape, and then stick this pattern on a fresh piece of metal and transfer all your cut and bend lines.

Biggest thing about making bends in aluminum is to deburr and burnish the edges where you will be bending, and to bend against the grain whenever possible.

dons · Post by **dons** » Thu Jul 12, 2007 11:59 am

Nice job Chad, and without the 'pro' tools either. Glad to know at least something from a Cessna is good enough enough for an RV

JohnR · Post by **JohnR** » Thu Jul 12, 2007 9:16 pm

RV7Factory wrote:
JohnR wrote:Your getting way ahead of me!
John, don't even start that. Remember the day when I was ahead of both you and Chad!?!?!

Nice work Chad!!! Can't wait to see it in person.

Shhhhh! I just want to keep Chad ahead of me so I have someone to call with questions. It's really handy to be able to pick up the phone and call when I know he just went through the same area.

Besides, you took time to have a baby!

cjensen · Post by **cjensen** » Thu Jul 12, 2007 11:33 pm

I think I'm gonna stop for a while now...

J/K...

Here's a pic of the painted part sitting in place. I think it came out pretty good...

More to come...but it doesn't really look to be very complicated at all.

Wicked Stick · Post by **Wicked Stick** » Fri Jul 13, 2007 11:44 am

Great job on the custom metal work Chad !

JohnR · Post by **JohnR** » Fri Jul 13, 2007 10:53 pm

Please don't stop.

The metal work looks really nice Chad. My friend Kevin will be quite interested in the outcome.

cjensen · Post by **cjensen** » Fri Jul 13, 2007 11:31 pm

Only kidding John...only kidding...

Thanks for the compliments guys!

jim_geo · Post by **jim_geo** » Sun Jul 15, 2007 12:56 am

Chad I have a question. How do the flaps lock in position?