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Preparation- Saw horses have been leveled individually in the respective
locations that they will be supporting the spars for the wing assembly. Aeronca wing assembly drawing 7-1
change E as a guide only. (You will find dimension
discrepancies depending on the serial number of
your plane in relation to the dates on the drawing change box, an example would be the rib spacing
dimensions) |
| 1 |
Assemble all ribs on the spars in their approximate positions except the root
rib. Leave them all loose.
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| 2 |
If the bushing for the wing fuselage attach brackets have been removed ,
glue them in the holes (with T-88) and attach the wing to fuselage
attach brackets immediately. Insert
bolts in all holes and tighten and cotter key all nuts on both brackets except the 1/4 “ bolt in the
rear spar bracket and the lower inboard hole on the front spar bracket. Don’t cotter key these two bolts
at this time. Leave the nuts loose.
 |
| 3 |
Install the spar to strut bracket. Glue
any loose bushings first. Leave the nuts loose on the middle bolt on
both front and rear spar. The rest of the nuts should be just barely snugged up , but don’t cotter key yet.
 |
| 4 |
Install the aileron pulley and center aileron support bracket with the
required large flat washers, barely snug nuts but
don’t cotter key yet.
 |
| 5 |
Install the three drag rod compression tubes with the six drag rod attach
plates. Tighten nuts and cotter key.
 |
| 6 |
Notch out the 3/8” square support blocks that are glued in the root rib wing
attach bracket openings. Be especially careful when cutting the notches for the wing attach brackets that
you keep the distance between the center line of the spars at 25” no more or no less, and that the
notches allow the bottom cap strip of the rib to seat on the bottom of the spar. Slide the root rib into
place but don’t attach it permanently until the wing
trammeling is done. |
| 7 |
Install the 44 inch drag rods in the wing root bay (bay one) Install drag rod
clevises under the two nuts that you had left loose in step three and snug the nut slightly, but don’t
cotter key yet. Screw the first of the two nuts that go on each
drag rod down until it aligns the
clevises that are under the two nuts that you just snugged up slightly. Now tighten the nuts at the clevis end
and cotter key. Back off the 10/32 nuts on the drag rods
until loose. |
| 8 |
Install the the 48 inch long drag rods that don’t have a clevis in bay two
with the head end of the rod at the front spar. Screw the two locking nuts on but leave loose. |
| 9 |
Install two 45 inch long drag rods with clevises in bay three with the clevis
under the middle nuts of the front and rear spar attach bracket that you left loose in step 4. Screw on
the two locking nuts but leave loose. |
| 10 |
Install the last set of 45 inch drag rods in bay 4 by
attaching the clevis
to the same bolts that are were used to attach the drag rods in bay 3. Now snug the strut attach bracket
nuts slightly as you did at the clevis end in step 7. Screw on the two locking drag rod nuts on all
drag rods in bays 4 and 3 and snug up the inboard nuts enough to aline the clevises under the two middle
nuts of the spar to strut bracket just as you did in step seven. Now tighten and cotter key the nuts
at the spar to strut bracket and loosen the 10/32 nuts at the other end. |
| 11 |
Install root rib. You will need to notch out the 3/8” blocks to fit around
the fuselage attach brackets. Be very careful that the distance between the spars remain at exactly
25”, CL to CL, when the root rib is attached. If necessary, put shims on the top of the spars to
lift the root rib so the bottom of
the root rib touches the spar. |
| 11b |
Glue any remaining truss pieces to any
ribs that had to be finished in place due to a splice or other spar repair.
 |
| 12 |
Trammel the wing by loosing or tightening the inboard 10/32 nuts. When
trammeled to your satisfaction, hold the inboard 10/32 nut exactly as it is and tighten the second
10/32 nut tight to lock the rod in place. Do not over tighten the drag wires. |
| 13 |
Tape any wires tightly that touch each other where they cross. |
| 14 |
Attach the outboard compression tube with the oversize washers and self
locking 10/32 nuts. Notch out washer, usually necessary, to clear the drag rod attach plate on the rear
spar. |
| 15 |
Re-check your wing for trammel. Tighten and safety all nuts that were left
snug and unsaftyed up to this point. |
| 16 |
Turn the wing over and nail the bottom cap strip of the root rib to the
bottom of both the front and rear spars. Turn the wing back over. If there is a gap between the top of the
spars and bottom of root rib top cap strip there should be a spacer inserted before nailing. Nail the top
of the root rib cap strip to the front spar. (Do not nail the root rib to the top of the rear spar at this
time.??) |
| 17 |
Adjust and align ribs then nail the rib rear front spar upright in two
places to the rear of the spar, except for the tip rib.
Then nail the rib rear spar upright to the front of the
rear spar. |
| 18 |
Glue the the 4 1/4 thick x 5/8 long and 7/8 wide wood spacer
pieces to the
top and bottom of the rear spar at the aileron rib and hinge bracket location. |
| 19 |
Attach the aileron rib and hinge bracket assembly using the large washers
and install cotter keys. |
| 20 |
Glue and nail aileron fairing strip end support and supporting corner blocks
onto rear spar. |
| 21 |
Fit the trailing edge to the full ribs and drill the drain holes, the holes
for attaching the trailing edge to the ribs, and the holes for
riveting the root rib extension to the trailing
edge. |
| 22 |
Glue in the 3/8 square fairing strip to rear of aileron ribs. |
| 23 |
Attach aileron cut out trailing edge to top rear of ailerons ribs |
| 24 |
Attach aileron cut out trailing edge to bottom of aileron ribs. |
| 25 |
Work the out board end of the 1/2 inch qtr round that will be used as the
leading edge of the rib nose blocks so that the 1 and 1/2 inches that extends past the nose of the last full
size nose block will slide into the interior of the wing tip bow as it angles down to the last full
aileron rib nose block. |
| 26 |
Install 1/2 inch qtr round to noses off all ribs except tip rib using glue
and no. 6 X 1 1/4” flat head brass wood screws. (Note drill pilot holes for both screw threads and screw
shank diameters) |
| 27 |
Nail rib nose block T section to top and bottom of all ribs. |
| 28 |
Insert wig tip bow prongs into ends of spars, over the end of the nose
leading edge, and into the outboard aileron hinge support. Screw to the nose and trailing end of the tip
rib with no. 6 X 3/4” brass wood screws. |
| 29 |
Install trailing edge. |
| 30 |
I'm Sorry... these notes are not
finished. |
| 31 |
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| 32 |
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