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Kupe's Zodiac 650B
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Date:  9-26-2017
Number of Hours:  3.00
Manual Reference:  
Brief Description:  Right Wing Preliminary Install

Got the right wing ready for final installation. Along with my helper, Jim, we installed and removed the wing multiple (maybe 6) times to trim the top skin enough to allow for final bolt alignment. Next we spent a significant amount of the session aligning the bolt holes. The challenge is a multi-dimensional problem in which every axis of the wing matters:
- Wing tip up/down - dihedral
- Wing tip fore/aft
- Wing tip twist - angle of incidence
- Wing spar depth into main spar
- Wing spar up/down inside main spar

The technique we're using for alignment is to balance the wing on a sawhorse strapped to a moving dolly. Once the wing spar is inserted into the main spar, the moving dolly sawhorse is moved outboard to match the 5.65 degree dihedral. Next, one of us got under the wing to push the wing spar up allowing an initial small bolt (AN3) insertion. From that point, the person on the wing tip made small adjustments in the various degrees of freedom mentioned above until small (AN3) bolts could slide into all the bolt holes. This process was repeated for the "bulletized" AN5 bolts I previously fashioned until the wing was aligned.

Last cleanup steps are to clean up the trimmed top skin edges, apply the rubber wing root fillet, put it back together and install/torque the final bolts.
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Right wing fully inserted (after trimming) and properly positioned.

Right wing fully inserted (after trimming) and properly positioned.

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Right wing root, looking aft, showing fuel qty wire, fuel hoses, aileron cables, and nav/strobe wire.

Right wing root, looking aft, showing fuel qty wire, fuel hoses, aileron cables, and nav/strobe wire.

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Three top

Three top "bullet" bolts and one bottom bolt in place.

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