Flaps on a Challenger Light Sport Aircraft

Building flaps on a Challenger Light Sport Aircraft modifications Construction and installation. Shortened ailerons on the plane does improve handling.  With full flaps the decent rate is increased and allows for a slower airspeed during landings due to increased lift.

Light Sport Aircraft

Flaps on an airplane allows for short field takeoffs and landings.  They really make a big difference and well worth the effort. 

Challenger Flap Position Indicator  |  Challenger Flaperons Position Indicator  |  Flap Hinge Video

Aileron and Flap construction on a Challenger

The wing tips were fitted and everything was marked for proper positioning along with the flaps.

I have a top mounted engine on my Challenger so my measurements may be just a bit different from yours.

With fiberglass wing tips the ailerons had to be cut to length.

Cutting the aileron leading edge.

Cutting the trailing edge.

Fitting the supplied aileron rib on the outboard end of the aileron.

Riveting the outboard rib

The aileron hinges are drilled and clecoed in place.

All the components of the flap hinge

The flap hinge is clamped in place and marked for drilling through the rear wing spar

Drilling the rear wing spar for the 1/4" bolt that will be used to attach the hinge.

Very important to place a washer on the top and bottom of the rear spar between the 1/14" angle and the spar for spacing.

1 1/4" long angle in position with washer underneath on both top and bottom.  This will give the needed spacing once the fabric is installed.

Now the flap hinge bracket is clamped to the angle on the inboard end.

The same is done on the outboard end of the flap then once marked it is drilled for the 1/4" attachment bolt which runs through the rear wing spar.

A view of the flap in position before the aileron is cut to length.

A carpenter's square is used to ensure the trailing edge of the aileron will be cut properly

Using a tubing cutter to cut the aileron trailing edge tube

Aileron trailing edge cut to length

Fitting the inboard rib on the aileron

Flap can now be temporarily installed and clearance can be rechecked

Clamping flap hinge bracket and checking aileron tube clearance

With everything in place the hinge bracket is drilled and bolted

Time to construct the cranks

Alodine applied before painting the flap cranks

Painted and hanging up to dry

Hinge assembly

Hinge tapped in place

Crank is clamped in place then riveted

Completed assembly

Aileron taped and ready for covering

Shortened aileron covered and ready for the iron.  Three passes at 250-300 and 350 degrees

Fabric ironed and ready for the first coat of Poly-Brush

Let's see if these flap hinges work   

Flaps on a Challenger Video (Broad Band)  High Speed 3+ MB    Flaps on a Challenger Video (dial up)  Dial Up (poor quality)


Challenger Flap Position Indicator

Indicator linkage
Micro Switch available
from Radio Shack

12 Volt Actuator can be purchased here Part #10136

DPDT Flap switch
and down position
indicator light


Flaperons Position Indicator

Flaperon Crank moved forward

Linkage for the indicator
available from Tower Hobbies

A view from the pilots seat



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