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Waynes Bearhawks
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Date:  6-15-2007
Number of Hours:  8.00
Manual Reference:  
Brief Description:  Redo wing jig

I decided to take a couple steps backward. I decided to redo the jig so I took all the wing parts apart and set them aside.

I built the jig with better support on both ends. The first thing I did was remake the support for the main spar outboard by shortening the arm by 1-1/2". I noticed that the 5" arm would flex up and down too much. I built supports for the rear spars that are bolted secure just like the main spar. I assembled the wings in the jig. I still had too much movement so I also secured the jig to the wall at the outboard end.

I made the support for the rear spar outboard end the same of the main spars with one modification. Since the three 1" support pieces span more than the opening in the rib I cut an angle on the arm so the wing will come off the jig with out hanging up on the rib. [UPDATE NOTE: If I were to do it again I would locate the outboard bottom support above the rear spar rather than below. There is interference with the outboard aileron pocket rib that I did not account for coming from below. Also I believe it would be easier to remove the wings from the jig.]

I reset the main spar with the laser level and braced the rear spar from the floor as necessary. I spent a lot of time shimming and securing everything in place. The wall support was a big help and held everything in place very effectively. It's going to be a little more difficult to move around the wings but I've been told that it's critical that things don't move during assembly and skinning. The jig is very solid now with no movement at all.
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Root End Support

Root End Support

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Outboard End Support Braced to Wall

Outboard End Support Braced to Wall

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Rear Spar Support Arm

Rear Spar Support Arm

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