Build The Ailerons - Top Flite P-47D THUNDERBOLT User Manual

4. Insert three #309 Robart Super Hinge
Points into the wing but do not glue them in
until after the wing and the flaps are covered.
Fit the flap to the wing and mark the locations of
the hinge points on the flap.
5. Use the Flap Drill Guide to drill the holes in
the flap just as you did in the wing.
6. Cut 1/4" off the end that fits into the flap of
the outermost hinge point. Test fit the flaps to the
wing with the hinges. Adjust the position (depth)
of each hinge in the flap and the wing until the
flap sets back in its original position before it was
first cut from the wing. Check the fit and run the
flaps through their complete range of motion.
Make any required adjustments until the flaps
swing freely. Remember, the flaps must close
flush against the wing TE.

BUILD THE AILERONS

1. Use a razor saw to cut the ribs and remove
the ailerons from the wing. Use a sanding block to
true the trailing edge of the wing and the leading
edge of the aileron.
2. Bevel one side of the shaped balsa Aileron
Horn Shim so it will match the angle of the rib
inside the aileron at the location shown on the
plans. When the base fits, apply glue only to the
side and the top of the base and then
permanently glue it in position.
3. Center and glue a 5/16" x 5/8" x 15" Aileron
Leading Edge Cap to the aileron. Use a razor
plane, then a sanding block to blend the leading
edge to the shape of the aileron. Trim the ends so
they are flush.
4. Use the marks made earlier on the outer
trailing edge of the wing (or the plans) to mark the
locations of the hinges on the aileron.
5. Draw a centerline on the leading edge of the
aileron. Cut the hinge slots in the aileron and
the wing.
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6. With the centerline of the aileron as a guide,
use a razor plane and a sanding bar to make a
bevel for the aileron deflection. Reference the
cross section on the plans.
7. Mark the location of the 1/8" x 3/4" x 3/4"
plywood Aileron Horn Block on the bottom of the
aileron. Cut away the sheeting, leading edge and
part of the balsa horn block mount until the horn
block fits flush with the aileron.
8. Glue the aileron horn block in position, then
use a sanding block to blend it to the shape of the
aileron. Test fit the aileron to the wing with the
hinges. Connect a Small Control Horn to the
clevis on the aileron pushrod. Mark the location of
the control horn on the horn block in the position
indicated on the plans. Drill 1/16" holes for the #2 x
3/8" sheet metal screws that secure the horn.
Some modelers temporarily connect the ailerons
for radio set-up prior to covering the model or this
can be saved until after covering.