Then it shall be done. I do want it to fly right and true as I have some make-up practice to do. Would like to get a good pattern in time.
Appreciated.
I have never regretted doing something better. I have sometimes regretted settling for "good enough".
Just to prove my sincerity, here are the hinge slots in the TE of the wing. First, the TE is built up from 5 layers - (2) 1/4x3/8, (2) 1/32x3/8, and (1) 0.025x3/8. The thinner one in the middle is interrupted to leave the right gap for the hinge. I made it from 1/32 sanded down between two pieces of .025 music wire. The extra 1/32 were to make the thing thick enough. It was designed to use 5/16 for that, but I didn't have enough of that of the right grade. I built up the outside parts with the 1/32 strips attached to each 1/4. Not surprisingly, that warped them about 2" each, towards the glued up side. That't because the heat of the adhesive setting up dried the inner edge of the 1/4", plus a tiny bit of shrinkage. If you let it sit for a few months it would straighten out, but that's not necessary. Then I attached the interrupted 0.025 to one side. Then I stuck on the other side, flat on the table with wax paper to keep it from sticking, and up against the ruler you see. When it was done, it was dead straight.
Second picture is it applied to the TE of the wing. I glued it on with the PICA Gluit, the planed and sanded it to match the airfoil. It is critical to get it centered, so I used small T-Pins through the hinge slots stuck into pre-set holes in the foam. Mostly, you could probably get away with just feeling it with your fingers. So now the hinges are in a perfectly straight line, and perfectly centered. Of course the same thing happens to the front of the flap.
Left to do is to put a very small groove right down the middle of the TE to accommodate the single hinge pin, and to ROUND OFF the sharp edge to about 1/4" radius. It looks generally better to leave it beautifully sharp, but rounding it off makes the flow over the flap more consistent. I will wait on both of those until the wing joined, and for the groove, after it is covered with graphite, to make the groove sharper in the final product. On the flap, it gets the usual wedge shape, with point left a little blunt (like .025,) and the edges at the flap surface radiused for the same reason as radiusing the TE.
Last is the picture of the completed installation. The gap is quite intentional but sealed with hinge sealing tape per the previous post. It is also quite beat up after one too many hits into the doorframes at the Signature Inn in Muncie over the last 8 years.
This is typical construction for these types of airplanes, but it shows you how much emphasis we put on details. Getting this right is far more important than whether you use a 18% airfoil or a 22% airfoil, saving 2 ounces, or the other silly arguments we have to kill time in the winter.
Brett