Figure 2. Taper the control surface sealing lips: First cover your working table with a soft cloth, such as a
fleece blanket to protect the wing surfaces. Next, apply masking tape onto the respective wing and control
surface (left panel). Now, use a sanding block to bevel the sealing lips carefully. Be careful to keep the “angle
of attack” constant over the whole length of the sealing lip, as seen in the middle panel. This will help to
generate a pointed leading edge (see right panel, red box) that won’t catch the wing surface, even after
coming back in from maximum deflection.
Installation of control horns in the wings
This is an especially important task because it will critically determine the function of the control
surfaces. Here, I describe the use of a “classic” cross-wise linkage system for ailerons (ails) and flaps.
Therefore, drill holes through the wing back shear web, the flap- and ail- shear webs. See figure 3.
Figure 3. Drill holes for control horn installation: You can use a round file to file a whole into the wing back
shear web exactly below the pushrod exit hoods (left panel). Alternatively, you can also use a small electric
drill with a rotary bit (middle panel). In this case however, be careful not to break through the wingskin. If
you place one finger underneath it you will feel the vibrations once you get critically close to the surface.
The flap and ail shear webs have to be treated the same way. In the end they should all look like in the right
panel.
Before you can glue the control horns into the holes of the flap and ail shear webs, they have to be
properly prepared. First, using a drill, you will need to carefully adjust them so that the clevises will
perfectly fit in the respective holes. Next, impregnate them with UHU endfest. See figure 4.
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