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Rob's REBVAIR Project
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Date:  7-28-2013
Number of Hours:  10.00
Manual Reference:  
Brief Description:  Wing attach Woes (part 2 of 3)

3) If you do 'set' the wing strut and fittings first (as described in part 1) drilling to final size for any of the wing or strut attach points should be done with the strut, wing, and fittings shimmed and clamped in place (see below). Drilling through the fuselage strut attach fitting below, (without the actual strut fitting sandwiched in place), by hand, results in thousands' of an inch changes in alignment that will change the final alignment of the strut within these fittings. My procedure ultimately was: bolt the strut to the upper wing attach fitting on the wing, rotate the strut up into position at the fuselage, then bolt with an AN5 bolt. Then shim it, clamp it, remove the bolt, and start drilling/reaming to final size. I have also found it imperative to know the size of the bolt you will be using before you buy the reamers. The Aircraft Spruce bolts I started with were 0.3730". The close tolerance bolts I purchased later were 0.3740", and the 'oversize' NAS6606-20X bolt I ultimately installed on one fitting was 0.3890" (As a precaution, I asked MAM if an AN7 bolt could be used safely here, and they said yes.) My experience as been that a reamer of exactly the same size as the bolt, when used either by hand, or especially in a hand held drill, will have enough slop that it will accept the bolt with a friction fit. On occasion, I have had to use a rat-tail file to trim the hole a bit further, but in my hands, even using a reamer 0.0005" greater than the bolt results in a slightly oversize hole. This is for 3/8" holes and bolts. The tolerances are different for the 1/4" bolts on the aft wing attach fittings. Following these guidelines, I am finally happy with the wing attach tolerances, and I will label each bolt to ensure it goes back into the right location.
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See 0.016

See 0.016" shims at the top and bottom of the fitting to prevent stressing the fixture when clamped

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clamping pressure holding the wing in place.

clamping pressure holding the wing in place.

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right rear wing attach

right rear wing attach

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