Flap Torque Tube Parts
To make the flap arms, I made templates out of 1/2" MDF and center punched the hole locations. Then using holes saws and lots of cutting oil, I drilled the tubing holes prior to cutting out the arms. After the holes were drilled, I used a plasma cutter to rough cut the arms and then final shaped using a 12" disc sander.
To help hold the parts for tacking, I drilled a 7/8" hole in MDF and made the tube longer than required. By driving the tube partially into the MDF, it kept the tube plumb and square long enough for me to tack the parts. Flap arm prepped and ready for welding. After welding, I will sand off the excess tube sticking through the flap arm.
