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Waynes Bearhawks
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Date:  1-29-2008
Number of Hours:  5.00
Manual Reference:  
Brief Description:  Flap/aileron hinge jig

I probably spent too much time putting the jig together but I was trying to get it right on.

First I made the "L" then I attached the tabs to the upright. I drilled the center hole on the top tab and the hole in the lower tab. Then I clamped a scrap piece of square tubing on the lower and clamped the tabs on one side and tack welded to the lower. Then I used two pieces of 5/8 tubing to clamp and tack the other side on.

I heated and reheated things and moved them more than once to get things just right. It's square and plumb so I guess it really doesn't matter how long it took.

After all the tabs were on I squared everything up and drilled the remaining holes. A piece of 3/4" plywood ripped 5/8 " wide works great as a center line on the lower tabs. The holes were located and reference off of that.

I did have one question come up when the holes on the middle tab were different on the CD and manual version than my copy of BearTracks. It turns out that the holes were originally displayed incorrect 1/16" above the reference line when in fact it should have been 1/16" below the reference line. If you look at the CD and the manual it looks like 2 holes. The BearTracks diagram was corrected and the one to follow.
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Before all Tabs are Drilled

Before all Tabs are Drilled

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3/4

3/4" Plywood Used for Reference Line

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Correct Hole Location

Correct Hole Location

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