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clojan(at)sbcglobal.net
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 Posted: Mon Feb 20, 2006 9:40 am Post subject: wing attachment and control cables |
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John: The wings were quite a hassle for me to get attached so I don't have a "better way" for you. I thought the flap arm was also in the up position but when it is down the arm is horizonal.
As far as the cables, I did attach everything to the stick and rudders and just left the other ends dangling until final assembly. One thing I did to make it easier to safety wire was to switch ends on the upper elevator turnbuckle. It looked impossible to safety wire it on the bottom of the stick buried in the bottom of the console so I attached it to the upper elev horn under the fiberglass. Works better there and when Nick came out to fresno to look at the plane I showed it to him and he said it would be fine. The rudder turnbuckles are also attached to the rudder horns outside of the plane. Jack (still waiting for the faa) in Los osos ca
john butterfield <jdbutterfield(at)yahoo.com> wrote:
hi list
after looking at my fuse i started wondering how hard
it would be to attach the wings. I was thinking of
taking off the rear protion of the wing gigs and just
seeing if the holes match, but like most of my
thoughts, something always seems to be different. any
suggestions on how to make the final attachment
easier.
also, is there plenty of play in the flap arm when
attaching to the actual flap. the plans seem
confusing to me in that the diagram shows the unit in
the flap down position, but looks to me like it is the
in the flaps up position.
as to the control cables, should i attach the cables
to the stick, and rudder and run them out to the
control surfaces and then attanch them later when
assembling the machine.
as you can see, my logical minds sometimes abandons me
regards
john butterfield
XL corvair
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tonyplane(at)bellsouth.ne
Guest
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| Posted: Tue Feb 21, 2006 8:12 pm Post subject: wing attachment and control cables |
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John,
The way I installed my wings was with the use of an engine hoist with
two straps supporting the wing about its span wise CG. You can get pretty
precise with the hydraulic lifting ram. I supported the wing on two padded
saw horses before lifting. I also used pieces of 2x4s at the aft channel to
prevent the straps from distorting the wing skin's aft edges and made sure
the straps would not distort the leading edge. I was able to trial fit and
install thewings without help.
I used handled 5/16 inch drift pins (you can also use modified 5/16 inch
bolts) which I tapered/bullet nosed to help align the holes in the wing spar
to center spar section. You want these aids to have a smooth surface finish
to prevent scratching or gouging the critical spar attach bolt holes, which
would create stress risers.
With the use of a mirror and flashlight, once you have one of the
center holes line up and pinned, careful use of the engine hoist will permit
you to align the other holes for pinning. (I procured a complete XL kit from
Zenith. Zenith match drills/reams the wing spars to center spar attach
holes, so you know that all 6 holes per wing should match up precisely).
After pinning, or if you wish temporarily bolting, the wing spars to the
center spar, you can then clamp the aft wing channel (spar) to the fuselage
fitting to check/adjust for alignment, incidence etc, before drilling for
the aft spar attachment.
After this is done, you can cleco the flaps to check for flap settings,
jack screw microswitch adjustments etc and also cleco the ailerons and
temporarily attach the bellcrank pushrod..
You may also at this time check your wing skin trim and trim as required
for the fuselage to wing seal fit.
As far as the aileron control cables, I had them installed in the wing
and attached to the aileron bellcrank with excess cable hanging out. I did
the final cable cut and swaging after I had drilled and temporarily bolted
the aft spar and clecoed the ailerons. I final rigged and safetied the
turnbuckles for the ailerons at the airport. One thing about the Zenith kits
is that they
provide more cable than you need so as to permit this.
The above is the way I did it before taking the wings and fuselage to the
airport for final assembly. I am sure there are many more ways to skin this
cat, though.
Tony Graziano
601XL N493TG 65+ hours
| Quote: | Time: 08:56:27 AM PST US
From: john butterfield <jdbutterfield(at)yahoo.com>
Subject: wing attachment and control cables
<jdbutterfield(at)yahoo.com>
|
| Quote: |
hi list
after looking at my fuse i started wondering how hard
it would be to attach the wings. I was thinking of
taking off the rear protion of the wing gigs and just
seeing if the holes match, but like most of my
thoughts, something always seems to be different. any
suggestions on how to make the final attachment
easier.
also, is there plenty of play in the flap arm when
attaching to the actual flap. the plans seem
confusing to me in that the diagram shows the unit in
the flap down position, but looks to me like it is the
in the flaps up position.
as to the control cables, should i attach the cables
to the stick, and rudder and run them out to the
control surfaces and then attanch them later when
assembling the machine.
as you can see, my logical minds sometimes abandons me
regards
john butterfield
XL corvair
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