I am SOOOO hacking this thing!

[captain_john]

This kills me. With all the precision that goes into an RV the flap hole pushrod cutout is the most vague and random cut yet!

I mean, really... how different could one RV be from another? Couldn't Van give more detail here? Maybe a pattern like Duckworks does for their lights???

This cutout has no precision and there is no clear cut explanation in the book. Just whittle it away!!!

I got one done tonight and I had to go to the gym and think about it. Now I am home and I still cannot believe how non-precision this hole is!

hahahaha Honestly!!! Really???

OK, I guess I will hack the other one tomorrow night after I bring Wyatt to the vet's for his annual checkup.

That ain't gonna be cheap either!!!

CJ

[hydroguy2]

hack away...I don't think it is possible to do it wrong. So far I've cut four of them....none the same!

[captain_john]

How IS that!?!

No need to ponder it I suppose.

It is just one of them enigmas I s'pose!?!

Guess I will have to fire up the chainsaw and get to it?

CJ

[captain_john]

...and Brian, think PRIME RIB!!!

Mmmmmeat!!!

CJ

[hydroguy2]

...and Brian, think PRIME RIB!!!

Mmmmmeat!!!

CJ

I better start training. Last year I wasn't in Otter Prime form, I got full sitting next to Chad.

[Brantel]

I was shocked with how much I had to open up those holes CJ. I just kept working on it till I could get em up and down with 1/8" clearance all around.

The hole ends up a weird shape and is way larger than one would think it should have been.

Mine was extra large since I used the Hex pushrod....

[cjensen]

...and Brian, think PRIME RIB!!!

Mmmmmeat!!!

CJ

I better start training. Last year I wasn't in Otter Prime form, I got full sitting next to Chad.

And I'm close enough to train on a weekly basis now!

[captain_john]

CHEATER!!!

CJ

lol

[captain_john]

Done hacking now!

The first one took me about an hour. The second one maybe ten minutes?

I am becoming a better hack I guess!?!

hahahaha

Bottom line, I have 45 degrees of fully motorized flappage now!

CJ

[Ronald Sutton]

The flap cut outs on both my RV4 are bigger then I wanted. They work as a cabin intake exaust ports for better cooling in the summer and better heater flow in the winter
Yaw String

[bruceh]

Start with something shaped like this.


I swapped out the CM-4S socketed rod end bearings for CM-4M's, along with a large washer, 1/4" spacer, and thin washers on an AN4-11A bolt. This will be much more secure and safer in case the rod end bearing fails.


Once it goes all the way up and down without touching, then give the hole a bit more clearance all the way around.

[Ronald Sutton]

nice fit. good work.

[BSwayze]

I used my dremel tool and a cutting bit to slowly enlarge the hole a little bit at a time. It's an iterative process, for sure. But once I had the first one finished and smoothed up, I taped a piece of paper over it, folded with the seam along the bottom of the side skin, folded at 90° also going underneath onto the bottom skin. Then I cut out the hole in the paper with a sharp knife. Then I used it as a template for the other side. Just fold the seam the other direction to make a mirror image hole, and a sharpie to mark it. Marking where the rivets are on the paper also helps to position it accurately on the other side. I hope that makes sense. It saved me a lot of time on the second one!