Section 40 Flap System

Section 40 Flap System

Step 1:Study Figure 1: carefully.

There are only two pre drilled holes in the inboard end of the WD-1013C Flap Torque Tube and four pre-drilled holes at the outboard end.

Step 2: Slide a WD-1013 Flap Torque Tube into the WD-1013A Flap Crank and align them by using the pre-drilled holes as shown.

Step 3: Cleco the WD-1013C Flap Torque Tube to the inboard most set of holes in the WD-1013A Flap Crank as shown in Figure 3. Match-Drill the flap torque as per the callout. Match-Drill 1/8 diameter holes from the outside in, using the pre-drilled holes in the flap crank as guides.

Step 4: Bolt the WD-1013A Flap Crank to the WD-1013C Flap Torque Tube as shown in Figure 4. Remove the clecos. Drill as per the callout.

Step 5: Slide a WD-1013B Flap Horn into the WD-1013C Flap Torque Tube as shown, in Figure.

Step 6: Drill a 1/4 dia. hole in the W-730 Bellcrank Jig using the dimensions shown in Figure 5.

Page 40-3

Step 1: Clamp the WD-1013A Flap Crank to a flat table as shown in Figure 1.

Step 2: The center Portion of the flap crank (along the welded seam will not be flush with the table due to the manufacturing process. This has been taken into account Do Not Modify this weldment.

Bolt the W-730 Bellcrank Jig to the WD-1013B Flap Horn using the hardware shown, This will set the angle of the flap horn relative to the flap crank.

Set the lateral position of the flap horn as per Figure 2.Clamp the flap horn into this position using a vise-grip (with padded jaws) placed over the inboard set of 1/8 inch diameter holes.

Leave vise grips in place while removing other clamps holding the assembly to the table. Note we just left all the clamps in place and drilled it with hand drill still attached to the table.

Page 40-4

Step 1: Bolt the WD-1013B Flap Horn to the WD-1013C Flap Torque Tube as per Figure 1.

Match-Drill #30 the flap horn at two places using the tube as a guide. Drill # 12 then Final-Drill 1/4.

Mark the parts so they can bee reassembled as drilled and identified as the parts to be used on the left side of the aircraft.

Step 2: Dissemble and deburr all parts.

Step 3: Repeat Step 1, Page 40-2 through Step 1 on this page for the flap torque tube and flap horn on the right side of the plane. The right side is a mirror of the left.

Step 4: Trim four F-1030 UHMW Bushings as per the callouts in Figure2. Only one area must be trimmed for clearance while the other two are optional for a small weight reduction. It is acceptable to radius the corners of the UHMW bushings approximately as shown in Figure 3.

Step 5: Slide one F-1030 UHMW Bushing onto each WD-1013C Flap Torque Tube as shown in Figure 3. This UHMW bushing will eventually be positioned to the inboard side of the system.

This will form the Right and Left Subassemblies. The left Subassembly is show in Figure 3.

Page 40-5

Step 1: Install the Left Subassembly into the 1 1/8 diameter holes in the F-1016F-L Inbd Footwell Rib as shown in Figure 1.

Install a second F-1030 UHMW Bushing onto the Left Subassembly as it passes through the F-1016-L Outbd Rib.

Step 2: Repeat step 1 for the Right Subassembly (shown partially installed).

Step 3: Slide the Left and Right Subassemblies outboard as shown by the Right Subassembly in Figure 1. Lower the WD-1013A Flap Crank into position then insert the ;left and right subassemblies into the flap crank.

Step 4: Rotate the F-1030UHMW Bushings into position with the thicker wall forward as per Figure 2. Bolt the UHMW bushings in place using the hardware called put on Figure 1.

Page 40-6

Step 1: Make two WD-1013J Spacers from AT6-058X3/8 as shown in Figure 1.

Step 2: Make one F-1066D Spacer from AT-058X3/8 as shown in Figure 2.

Step 3: Make one F-1066E Spacer from AT-058X3/8 as shown in Figure 3.

Step 4: Drill a 1/16 diameter hole through the upper lip of the ES 85615-10 Flap Motor to accept safety wire as shown in Figure 4. This hole should exit outside the profile of the jam-nut (but within its outside diameter) as shown in Figure 4> Avoid removal of the jam nut and rod end since the length of the assembly has been set at the factory.

Page 40-7

Step 1: Bolt the WD-1013A Flap Crank to the WD-1013C Flap Torque Tube as per the callouts in Figure 1.

with the F-1066B-L Flap Motor Angle free from the bracket, slip the AN4-20 bolt through the F-1066E Spacer, the ES 85615-10 Flap Motor lug, and the F-1066D Spacer. Lower this assembly onto the F-1066A Bracket and then insert the bolt into the F-1066B-R Flap Motor Attach Angle. Add the washers and nut as per the callout but do not tighten.

Bolt the F-1066B-L Flap Motor Attach Angle to the F-1066A Bracket using the hardware called out. Snug down the AN-310-4 nut. Check for interference between the flap motor and flap motor attach angles and adjust the spacers if/as required t eliminate any interference.

Bolt the flap motor's rod end to the flap crank using the hardware called out. Adjust the length of the spacers for a net fit into the resulting gaps between the flap crank and the flap motor rod end. Tighten the self-locking nut.

Remove the castle nut just enough to remove end play but not so much as to add friction. Add the cotter pin to the AN4-20 bolt as per the callout.

Step 2: Route the safety wire through the new hole in the ES-85615-10 Flap Motor around the WD-1013J Spacer and back to the flap motor, winding it securely as shown in Figure 2.

Page 40-8

Step 1: Bolt the WD-1013B Flap Horn to the WD-1013C Flap Torque Tube as per Figure 1. The left side of the aircraft is shown in Figure 1. Repeat this step for the right side of the aircraft.