The first thing to do is assemble the flap handle actuating tube, it is a simple matter of inserting the spring and tube inside the larger flap handle tube,(A). Builders often start with a spring that is too long and snip the spring off until the desired button pressure is achieved. Then you take the curved and detented flap position part (B), and insert it through the slot in the handle, and the tube that you put inside. Then the assembly gets sandwiched in between two tubes, (C), and a bushing, (D), is slid in place to hold it. You then bolt the detented flap position part at the top and bottom. The bushing gets drilled in place with the tube, and a cotter pin inserted, just like the rudder pedal bushings. Please note that in the following pictures, some fasteners are just temporary, or have temporary nuts on them.


Cables for the flap system are galvanized or stainless steel 1/8 7×19. The first cable is made up and connected to the bottom arm of the flap handle using a cable shackle, (E). It then runs through the lower two fairleads, around the first pulley and then under and around the second pulley. Make your cable so that you have approx 10 inches of cable after the second pulley, this is when the flap handle is in it’s lowest position (flaps 0). This cable then gets attached to the bottom of a triangular plate with a cable shackle. Remember to make the cable guards for the pulleys. What you are looking for in the final installation is to have the steel triangle as close to the pulley as possible when the flaps are in the full down position. This assures max travel of the flaps.



You will then need to make up two more cables that run from the triangle plate to the flap control horn on each wing. A turnbuckle on each cable end gets attached to the upper holes in the triangle plate, this will be for adjusting the cables later after you connect to the flaps, so make sure you leave adjustment in the right direction. The cables then run up to their respective pulley’s at the rear baggage station, go forward through two more fairleads before running under the final pulley just aft up of each flap control horn.




The final attachment is connecting the cable to the flap horn with another cable shackle. Here is a place that at times a larger cable shackle is used (1/4″) to help avoid interference with the wing rear spar end. This space is very tight. So be sure your cable, the flap control horn, or any of the attach hardware do not rub on the wing rear spar end as the flap moves through its travel range.
Remember to make sure the flap control horn (at the wing) is in the flaps up position, and the flap control handle is in it’s lowest position (closest to the floor), when making up your cable lengths. The position (angle) of the flap control horn is shown on the plans with the flaps all the way UP. Measure that angle and position it as shown on the plans.

These two drawings show the flap handle assembly, courtesy of builder Bruce Case:
Flap Handle Drawing A
Flap Handle Drawing B