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34-03 to 05 Flap Torque Arm & OP 54 Flap Position Kit

Priming

Before the torque tubes are installed, Vans suggest you prime the inside of the tubes.

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So to clean and scuff the tube interiors I pushed a roll of Scotchbrite through several times, and then did the same with my usual paper towels, soaked in Acetone, to clean and degrease.

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Then the messy bit! Following the advice on the first page of Section 5 in the manual, I poured primer into the tubes, rotating them to get complete coverage.

I found it less messy to pour in the primer from a little bottle with a spout, attempting to get the excess back into the original pot.

Good luck : )

Safety Wire

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You have to drill a little hole in the Linear Extension Shaft so that safety wire prevents the jam-nut from rotating.

I was expecting trouble with this, due to the angle, but it actually went very easily.

Flap Position Sensor

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As per OP Section 54 I drilled the hole in the crank for the Flap Position Sensor pushrod.

I then primed inside the crank tube as well.

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More fun crimping on some micro Molex terminals … it’s been a long time since I did this when wiring the elevator trim servo, so for once I found one of my old blog posts useful to remind me of how I did it last time : )

Pushrod

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Pliers soon sorted the pushrod bend …

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… but rather than fix the length of the pushrod by a z-bend on the other end, I used a “Quick Link” as used in Radio Control planes. That way I’m hoping to fine tune the required travel datum.

Inserting the Torque Rods

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Even with the powder coating sanded smooth on the tube edges they were a tight fit in the bushes … but I needn’t have worried, because when I smeared on some grease they slid in much more easily.

I adjusted the flap actuator position by motoring it slowly with a 9v battery … this enabled me to set the flap position sensor position prior to tightening its attachment bolts.

So that’s this section done. Next up … the Upper Forward Fuselage!

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