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Flap 17

Flap 18

Flap 19

Flap 20

Flap 21

Flap 22

Co-pilot flap problem

The "Z" Spar was installed one inch aft of the correct location.

Flap end plates are not in correct location.

Flap cross section is not correct.

Flap 24

Flap 25

Flap 26

Flap 27

Flap 28

Flap 29

Dismantle flap

Separate the upper skin from the z spar and end ribs.

Remove the upper skin

Z spar, end ribs and lower skin will be used in the new flap mold.

Flap 35

Flap 36

Flap 37

Flap 38

Flap 39

Flap 40

Flap 41

Flap 42

Flap 43

Assemble Flap Plug

Build flap plug with a correct co pilot flap.

Mount flap on wood frame, build up ends with foam and body fillers.

Sand fillers and spray paint plug for smooth finish.

Flap 50

Flap 51

Flap 52

Flap 53

Flap 54

Flap 55

Flap 56

Flap 65

Flap 66

Flap 67

Flap 68

Flap 69

Flap 70

Flap 71

Flap 72

Flap 73

Flap Mold Construction

Apply release tape to plug

Build Mold side frames

Make mold ribs, measure and cut glass reinforcement

Flap 80

Flap 81

Flap 82

Co-Pilot Flap Construction

Locate "Z" spar in mold

Cut and trim foam core

Cut fiberglass parts

Layup glass and foam core

Vacuum bag assembly

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