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Flap Rod Draft

Frankster

Active Member
I solved the flap rod draft in my RV7 for about $2. I designed and 3D printed a cube to go over the hole in the fuselage that the flap rod travels through. attached to the top of the cube is a party balloon with the top cut off that is attached to the top of the cube with a zip tie, then attached to the flap rod itself. The cube is glued in place with Shoe Goo or Pro Seal. I have flown it and the draft is completely eliminated. When installing disconnect the flap rod at the top and let the top of the rod drop to the hole in the fuselage while the flap drops vertical to the ground. Now you can apply the glue to the cube, set it in place, and let it dry without interference. Once dry have someone help by lifting the flap while you guide the top of the flap rod through the top of the balloon and terminate the flap rod to the horn. then fold the balloon around the flap rod and secure with a small zip tie... done.
Photos and a video below at the links. If anyone wants the .STL file to print it just send me a message with your email address to send it to. Sorry, not sure how to get the images to post, just clink on the links.

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https://www.facebook.com/100002708764235/videos/a.4159579657475619/1236704090155003

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Brilliant

Simple effective, and I think a brilliant solution! Thanks for sharing Frank !
 
Excellent solution Frank!

Now I need a 3d printer. That cold draft up my armpit is really uncomfortable. I like your design.

Maybe you and Steve Melton (& Amanda) can work a deal.
 
Good work. Would you please report back with the lifespan of the balloon. It may need an upgrade. What do the finished parts weigh?

Now, go after the corrugation in cargo bulkhead.
 
Good work. Would you please report back with the lifespan of the balloon. It may need an upgrade. What do the finished parts weigh?

Now, go after the corrugation in cargo bulkhead.


You may have to wait until my annual next October unless I heart a loud "POP" before then. The plastic parts are 19.91 grams a piece (.04 lbs).... The plastic only has an infill of 15%, it is not solid. I filled in the corrugations in my upper and lower bulkhead with big gap expanding foam at the edges where it mates up years ago, not an issue.
 
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Thanks Frank, what an elegant simple solution. I still have a long way to go but was working on flap drive last month and was wondering about this very issue.
I’ll pm you with my email address for the file. Thanks again, Max
 
Related efforts towards the same end:

- Fill the corrugations in the aft bulkhead with triangles of closed cell foam weatherstrip adhered to the panel. Don't know if it helps but it makes me feel warmer!

- Add boots to the aileron push tubes where they exit the wing root. Mine are stitched from cordura (leather would be nice too) and they slide on the tube, protruding into the wing root and allowing the boot to flex but not inhibiting the nice feel of the controls. Along with boots on the stick bases, there is no air entering from there at all.

I feel no drafts in my plane, even without the flap rod seal, but that would close up the last hole.

Keep it up with the innovation!!

Cheers
 
Related efforts towards the same end:

- Fill the corrugations in the aft bulkhead with triangles of closed cell foam weatherstrip adhered to the panel. Don't know if it helps but it makes me feel warmer!

- Add boots to the aileron push tubes where they exit the wing root. Mine are stitched from cordura (leather would be nice too) and they slide on the tube, protruding into the wing root and allowing the boot to flex but not inhibiting the nice feel of the controls. Along with boots on the stick bases, there is no air entering from there at all.

I feel no drafts in my plane, even without the flap rod seal, but that would close up the last hole.

Keep it up with the innovation!!

Cheers


Ya, I filled the bulkhead triangles by using expanding foam for around windows and then cut off the excess and used the aileron seals from Classic Aero Designs. I still had a draft from the flap rods until this.
 
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