express assembly manual section 3 f5-rg/ft wing assembly ... wing manual 2010_pdf/procedur… ·...
TRANSCRIPT
EXPRESS ASSEMBLY MANUAL SECTION 3 F5-RG/FT WING ASSEMBLY
©2000 Express Aircraft Co LLC Rev. 7/10 Page 3.010-1
Procedure 3.010A
INTRODUCTION
In this procedure…
You will construct both wings, starting with the left wing. The work will include
assembling the wing structure, installation of controls, fuel system, miscellaneous
systems, and finally, wing closeout. When the left wing is completed, it will be
placed out of the way, so that the right wing can be constructed.
WHAT YOU NEED TO DO FIRST
Before starting construction on the wing, you should order any parts that are not included in the
kit that you will need during these procedures. Ordering now will assure that the parts are
available for installation when needed. You can order these parts directly from Express Aircraft,
or shop around. Following is a list of the parts needed during wing, construction, their quantities,
and whether they are mandatory.
PARTS TO BE ORDERED:
Mandatory Description Qty
Yes Fuel Sending Unit 2
Yes Pitot-Static Unit 1
Yes Antenna 1
No Navigation/Strobe Lights 2
EXPRESS ASSEMBLY MANUAL SECTION 3 F5-RG/FT WING ASSEMBLY
©2000 Express Aircraft Co LLC Rev. 7/10 Page 3.010-2
Step 1. WING JIG SAWHORSE ASSEMBLY
DESCRIPTION:
Sawhorses of specific dimensions are required for supporting the wing saddle jigs. Four are
required per wing, and the same four can be used for each wing. Material quantities given are
for 4 sawhorses. You can cut all of the parts at once, but we suggest you assemble one at a
time.
MATERIALS:
Description Qty
1” x 4” Fir, 8' length (3/4" x 3 1/2" actual) 10 3/8" Grade A Plywood, 4' x 4' 1
Leg 16
Outer Gusset 8
Lower Cap 8
Inner Gusset 8
Main Web 4
Galvanized Box Nail, 5d, 1 1/4 length 144
Drywall Screw, #8, 1 1/2" length 16
Wood Glue
PROCEDURE:
A. Cut the gussets out of plywood.
B. Cut the legs, lower caps, and main web from 1” x 4” fir. Bevel both ends of the legs, making
both bevels parallel. Bevel both ends of the lower caps, making bevels in opposite directions.
EXPRESS ASSEMBLY MANUAL SECTION 3 F5-RG/FT WING ASSEMBLY
©2000 Express Aircraft Co LLC Rev. 7/10 Page 3.010-3
Fig. 10.1 Dimensions of Sawhorse Parts
Fig. 10.2 Wing Sawhorse Dimensions
EXPRESS ASSEMBLY MANUAL SECTION 3 F5-RG/FT WING ASSEMBLY
©2000 Express Aircraft Co LLC Rev. 7/10 Page 3.010-4
C. Glue and nail the outer gussets to the legs.
Fig. 10.3
D. Glue and nail the lower caps to the outer gussets and legs.
Fig. 10.4
EXPRESS ASSEMBLY MANUAL SECTION 3 F5-RG/FT WING ASSEMBLY
©2000 Express Aircraft Co LLC Rev. 7/10 Page 3.010-5
E. Apply glue to the sawhorse main web where it meets the outer gussets and lower caps. Nail the
outer gussets to the ends of the web. Screw the web to the lower caps, using drywall screws.
Fig. 10.5
F. Glue and nail the inner gussets to the legs and lower caps.
Fig. 10.6
EXPRESS ASSEMBLY MANUAL SECTION 3 F5-RG/FT WING ASSEMBLY
©2000 Express Aircraft Co LLC Rev. 7/10 Page 3.010-6
Step 2. WING SADDLE JIG ASSEMBLY
DESCRIPTION:
Before the wing can be constructed, it must be supported in a jig. The wing saddle jig consists of
four saddles contoured to fit the upper wing skin. These are attached to the wing sawhorses, which
are then aligned and glued to the floor. The templates provided are used to cut and drill the saddles
to shape. The saddles are good for the left and right wing jigs, so only one set of four (4) is
required.
MATERIALS:
Description Part No. Qty
Wing Jig Saddle 1 Template 111-19-001 1
Wing Jig Saddle 2 Template 111-19-002 1
Wing Jig Saddle 3 Template 111-19-003 1
Wing Jig Saddle 4 Template 111-19-004 1
3/4" Plywood, 4'x 5‟ minimum
Adhesive Spray
Sand Paper
TOOLS:
Jigsaw or Band Saw
Drill Motor and 1/4" Dia. Drill Bit
EXPRESS ASSEMBLY MANUAL SECTION 3 F5-RG/FT WING ASSEMBLY
©2000 Express Aircraft Co LLC Rev. 7/10 Page 3.010-7
PROCEDURE:
A. Cut out each template approximately 1/2" outside the lines.
B. Arrange the templates on the plywood so the least amount of wood is wasted, but so each
template is accessible with the saw. If using a 4'x 5‟ sheet of plywood, use the suggested layout in
the illustration. (Fig. 10.7)
Fig. 10.7 LAYOUT OF TEMPLATES ON PLYWOOD
EXPRESS ASSEMBLY MANUAL SECTION 3 WING ASSEMBLY
©2000 Express Aircraft Co LLC Rev. 7/10 Page 3.010-8
C. Spray adhesive spray on the plywood for one saddle, and on back of one template, and let it
get tacky to the touch. Attach the template to the plywood. Repeat for each saddle.
D. Cut out each template using a jigsaw. Cut as close as possible to the lines, leaving all lines
visible.
E. Sand the edges of the saddles that meet the wing skin, so that the edge is on the line of the
template, and no dips or bumps can be felt in the saddle.
F. Drill the holes located on each template, using a 1/4" drill bit. Leave the template on the
saddle after cut out, as the information printed on the template will be needed later.
Step 3. LEFT WING SADDLE JIG ASSEMBLY
DESCRIPTION:
After the wing jig saddles are completed, they are attached to the wing sawhorses. The
sawhorses are then located and attached to the floor.
MATERIALS:
Description Part No. Qty
Wing Sawhorse Assembly Builder Supplied 4
Wing Jig Saddle 1 111-19-001 1
Wing Jig Saddle 2 111-19-002 1
Wing Jig Saddle 3 111-19-003 1
Wing Jig Saddle 4 111-19-004 1
Upper Wing Assembly, Left 111-11-050-01 1
Bolt, ¼ -20 x 2 Builder Supplied 8
Washer ¼” Builder Supplied 8
Nut, 1411-20 Builder Supplied 8
Hot Glue Builder Supplied
Wood Blocks Builder Supplied
TOOLS:
Chalk Line Measuring Tape Plumb Bob Drill Bit 1/4"
Marker 2' Carpenters Square Hot Glue Gun Carpenters Level
Masking Tape Spring Clamp (2) Drill Motor Wrench 7/16 (2)
EXPRESS ASSEMBLY MANUAL SECTION 3 WING ASSEMBLY
©2000 Express Aircraft Co LLC Rev. 7/10 Page 3.010-9
A. To draw location lines on floor, snap a 13-foot long chalk line on the floor to represent the
main spar centerline. Allow at least 3-feet clearance from each end of the line to any wall. Also
allow 4-feet clearance to either side of the line. Starting 12" In from one end of the line make four
marks along the centerline with a marker, spaced 44.7" apart. Label them saddle 1 through saddle
4 consecutively, with saddle 1 being the inboard saddle. (Fig. 10.8)
Using a 2‟ carpenters square
and a marker. Make four-4‟
lines perpendicular to the
centerline through the saddle
location marks. These are the
location lines for the saddles,
which you will use to align the
sawhorses, so mark them
visibly. Also make a mark on
each 4‟ line where the spar
centerline intersects. These
marks will be used later for the
right wing, as the chalk line
may have faded in time.
Fig. 10.8
B. To attach saddle 1 to sawhorse, locate saddle 1 and one sawhorse. Center the saddle
approximately on the sawhorse web with the template side out. Allow the bottom of the saddle to
hang 1/2" below the bottom of the web. Using 2 spring clamps, clamp saddle 1 to the sawhorse
web, leaving clearance to drill the holes. The leading edge (Forward) should be to the left as you
face the saddle/sawhorse assembly from the saddle side. Drill one of the 1/4" holes through the
saddle hole, and into the sawhorse web. Attach finger tight with a bolt, washer, and nut.
EXPRESS ASSEMBLY MANUAL SECTION 3 WING ASSEMBLY
©2000 Express Aircraft Co LLC Rev. 7/10 Page 3.010-10
C. To place saddle 1 sawhorse on location lines, spring clamp the plumb bob string to the spar
centerline marked on the template, allowing the plumb bob to hang to the floor. Locate the saddle
and sawhorse parallel to the saddle 1 location line, so the plumb bob is at the saddle 1 mark. The
saddle should be on the side of the sawhorse web away from the other saddle lines. (Fig. 10.9)
Line up the saddle with the saddle 1 location line by checking with the plumb bob at different
points. When the saddle and sawhorse are aligned, hot glue the sawhorse legs to the floor. To
prevent accidental kicks that may loosen a sawhorse leg, hot glue some small scraps of wood such
as 1 x 2 up against each leg.
Fig. 10.9
D. Make one more check with the level on the bottom edge of the saddle. If it is not level, loosen
the spring clamp, adjust, and re-clamp. Drill the second hole through the saddle hole and into the
sawhorse web. Attach with bolt, washer, and nut, and tighten both nuts securely with a wrench.
E. Repeat steps 2 through 4 for saddle 4. Make sure that the saddle is mounted on the same side
of the sawhorse as saddle 1, and that the leading edge (Forward) is at the same end.
EXPRESS ASSEMBLY MANUAL SECTION 3 WING ASSEMBLY
©2000 Express Aircraft Co LLC Rev. 7/10 Page 3.010-11
F. To set up saddles 2 and 3, locate saddle 2 and one sawhorse. Center the saddle approximately
on the sawhorse web with the template side out. Allow the bottom of the saddle to hang 1/2"
below the bottom of the web. Using 2 spring clamps, clamp saddle 2 to the sawhorse web. Spring
clamp the plumb bob string to the spar centerline marked on the template, letting the plumb bob
hang to the floor. Locate the saddle and sawhorse parallel to the saddle 2-location line, so the
plumb bob is at the saddle 2 mark. The saddle should be on the side of the sawhorse web away
from the other saddle lines.
Line up the saddle with the saddle 2-location line by checking with the plumb bob at different
points. When the saddle and sawhorse are aligned, hot glue the sawhorse legs to the floor. Now
remove the clamped saddle. Repeat for saddle 3. (Fig. 10.10)
Fig. 10.10
EXPRESS ASSEMBLY MANUAL SECTION 3 WING ASSEMBLY
©2000 Express Aircraft Co LLC Rev. 7/10 Page 3.010-12
G. It‟s time now to place upper wing skin on saddles 1 and 4. Place a strip of electrical tape on
the edge of saddle 1 and 4 where the wing skin will make contact to prevent scratches.
To locate the wing skin on the jig, you will use the center of the main spar, and the rib G-
location line. On models built after year 2000, a reference line has been scribed into the spar cap
at BL (Butt Line) 36.00, from which you will measure a given distance. Take all measurements
along the center of the top spar cap. BL 36.00 will be approximately 34” from the inboard end
of the main spar. To find the rib G-location centerline, measure 140.00" outboard from BL 36.00
and label it BL 176.00.
With at least one person at each end, invert the left upper wing skin and place it in the jig. The
center of the main spar should line up with the main spar centerlines on saddles 1 and 4. The rib G-
location line should line up directly above saddle 4.
H. To setup saddles 2 and 3, place a strip of electrical tape on the edge of saddle 2. Get under the
wing skin and position saddle 2 in place. Slide it along the sawhorse web until the most contact is
made with the wing skin, put a slight amount of upward pressure on it, and clamp it in place. The
lower edge should be approximately level. Drill both holes through the saddle holes and into the
sawhorse web. Attach with bolt, washer, and nut and tighten both nuts securely with a wrench.
Repeat for saddle 3.
I. Anchor jig to floor. The easiest, non-destructive (floor) method is Bondo.
Apply Bondo to sawhorse feet & floor. When finished, sand off!!
Other methods: Lag bolt, Anchor bolt, and/or bracket and screws.
J. Secure wing assemblies to sawhorses.
Methods:
(A) Hot glue between saddles & skin.
(B) Bondo between saddles and skin.
(C) 1-1/2” wood screws through fwd. joggle & saddles, and aft trailing edge &
saddles. (4 places ea.)
*Now you are ready to begin left wing assembly (Step 5, This section), starting with
installation of forward and aft shearwebs. Upon completion of the left wing, you will
return to the following right wing saddle jig assembly instructions.
EXPRESS ASSEMBLY MANUAL SECTION 3 WING ASSEMBLY
©2000 Express Aircraft Co LLC Rev. 7/10 Page 3.010-13
Step 4. RIGHT WING SADDLE JIG ASSEMBLY
DESCRIPTION:
When the left wing is completed and stored out of the way, the left wing jig can be modified for
the right wing, the saddles can remain bolted to the sawhorses. The sawhorses must be pried from
the floor and relocated. Also, the level of each saddle must be checked, and corrected if
necessary.
PROCEDURE:
A. Pry the sawhorses from the floor. Label the location lines on the floor in the opposite in the
opposite direction as the left wing layout (i.e. saddle 1 becomes saddle 4; saddle 2 becomes
saddle 3; etc.).
B. To place saddle 1 on location lines, locate saddle 1 and its sawhorse. Spring clamp the plumb
bob string to the spar centerline marked on the template, allowing the plumb bob to hang to the
floor. Locate the saddle and sawhorse parallel to the saddle 1 location line, so the plumb bob is at
the saddle1 mark. The saddle should be on the side of the sawhorse web toward the other saddle
lines. The leading edge (Forward) should be to the left as you face the saddle/sawhorse assembly
from the saddle side. (Fig. 10.11)
Fig. 10.11
EXPRESS ASSEMBLY MANUAL SECTION 3 WING ASSEMBLY
©2000 Express Aircraft Co LLC Rev. 7/10 Page 3.010-14
Line up the saddle with the saddle 1 location line by checking with the plumb bob at different
points. When the saddle and sawhorse are aligned, hot glue the sawhorse legs to the floor. To
prevent accidental kicks that may loosen a sawhorse leg, hot glue some small scraps of wood such
as 1” x 2” up against each leg.
C. Level and tighten saddle 1. Check with the level on the bottom edge of the saddle. If it is not
level, loosen the bolts, removing one bolt completely. Level the bottom edge of the saddle, and
clamp in place. Drill a 1/4" hole through the saddle and sawhorse web, approximately 1" in from
the obsolete hole. Attach with a bolt, washer, and nut, and tighten both nuts securely with a
wrench.
D. Repeat steps 2 and 3 for saddle 4. Make sure that the saddle is mounted on the same side of
the sawhorse as saddle 1, and that the leading edge (Forward) is at the same end.
E. To set up saddle 2 and 3, locate saddle 2 and its attached sawhorse. Spring clamp the plumb
bob string to the spar centerline marked on the template, allowing the plumb bob to hang to the
floor. Locate the saddle and sawhorse parallel to the saddle 2-location line, so the plumb bob is at
the saddle 2 mark. Line up the saddle with the saddle 2-location line by checking with the plumb
bob at different points. When the saddle and sawhorse are aligned, hot glue the sawhorse legs to
the floor. Remove the clamped saddle from the sawhorse. Repeat for saddle 3.
F. To locate the wing skin on the jig, you will use the center of the main spar, and the rib G-
location line. On models built after year 2000, a reference line has been scribed into the spar cap
at BL (Butt Line) 36.00, from which you will measure a given distance. Take all measurements
along the center of the top spar cap. BL 36.00 will be approximately 34” from the inboard end
of the main spar. To find the rib G-location centerline, measure 140.00" outboard from BL 36.00
and label it BL 176.00. With at least one person at each end, invert the left upper wing skin and
place it in the jig. The center of the main spar should line up with the main spar centerlines on
saddles 1 and 4. The rib G location line should line up directly above saddle 4.
G. To set up saddles 2 and 3, get under the wing skin and place saddle 2 in place. Slide it along
the sawhorse web until the most contact is made with the wing skin, put a slight amount of upward
pressure on it, and clamp it in place. The lower edge should be approximately level. Drill 2 holes
approximately 1" in toward the center from the existing holes, through the saddle and sawhorse
web. Attach with bolt, washer, and nut, and tighten both nuts securely with a wrench. Repeat for
saddle 3.
EXPRESS ASSEMBLY MANUAL SECTION 3 WING ASSEMBLY
©2000 Express Aircraft Co LLC Rev. 7/10 Page 3.010-15
H. Anchor jig to floor in same manner as left wing.
I. Secure wing assemblies to sawhorses in same manner as left wing
*Now you are ready to begin right wing assembly, starting with installation of forward
and aft shearwebs.
Step 5. BEGIN WING ASSEMBLY
For this procedure, the following parts will be required:
Materials: ½” 5lb. foam 2 core 2 pre-lam (Shearwebs).
Step 4. Part Number Description
Quantity
111-11-051/052 Forward Shearweb 2
111-11-055/056 Aft Shearweb 2
½” 40 lb. foam 40 lb. Foam Hardpoints 9
A. Locate forward and aft shearweb locations.
1) From Centerline mark on spar cap, at BL 176 (Outboard joggle), measure 14 ¼” towards
forward edge of skin and 6 ½” towards aft and make respective marks. Now move to inboard end
of wing assembly. From centerline of spar cap, at BL 20.00, measure 18 ¾” towards forward
joggle area, and 20 ¾” towards aft, and make respective marks. Next, snap chalk line forward
and aft, end-to-end, lengthwise. Overwrite snapped line with felt pen to indicate location of
shearwebs, clearly.
2) Prep 3” to 4” wide strip, lengthwise at each shearweb location, or line, to bond shearwebs to
skin. Also prep forward and aft surfaces of shearwebs, 2” up from bonded edges, on front and
back edges of shearwebs, for shearweb tie-in laminates.
EXPRESS ASSEMBLY MANUAL SECTION 3 WING ASSEMBLY
©2000 Express Aircraft Co LLC Rev. 7/10 Page 3.010-16
3) Prior to cutting shearwebs to length and height, it is preferable to butt-splice (join end-to-end)
the pieces of the forward and aft shearwebs at a butt line (BL) common to a rib location i.e. BL
91.12. For this purpose, apply 2 layers of 3” tapes. Overlap splice. Allow to cure and then install
rib. This strengthens the joint with rib installation.
Note: Do not trim shearweb height until after glassed in (B-2, this section). Then snap line end-
to-end and trim.
4) Using a bubble level, plumb and anchor webs in place with hot glue. (Fig 10.12). Locate
forward shearweb on forward side of marked line from BL 179.00 (Wing tip joggle) to inboard
skin E.O.P. Locate aft shearweb on aft side of marked line from wing tip joggle to inboard E.O.P.
Fig. 10.12
EXPRESS ASSEMBLY MANUAL SECTION 3 WING ASSEMBLY
©2000 Express Aircraft Co LLC Rev. 7/10 Page 3.010-17
5) Q-Cell both sides of forward and aft shearwebs at contact area, along entire span.
6) Cut dozens of 3” wide, 45˚ bias ply tapes off of 50” wide, 7781 fiberglass cloth. Roll up and
store in shoebox or equiv.
*SHOP TIP*
To help hold shearwebs in position during hot gluing and Q-Cell operation, evenly space small
1”x 4” boards between spar caps and shearwebs. Place heavy objects in center of boards.
(Fig. 10.13)
Fig. 10.13
Allow Q-Cell to “cure” before continuing!
Note: Extra tapes, not used now, will be used later - i.e. Rib Install.
7) Prep forward and aft shearwebs for Laminates. Each wing will also need (4)
6” x 60” strips of uni-directional cloth and (2) 8” x 62” 7781 tapes, or rolls, along with 3” rolls.
8) Prior to laminates, with Q-Cell radius hardened, layout rib locations at this time. Locate BL
36.00 on spar cap. Approx. 34” from inboard end of spar will be a line scribed into spar. This
will be your reference line (BL 36.00) throughout the wing assembly. *Do Not Sand Or
Remove This Line*
9) From BL 36, measure inboard on spar cap 12 ½” and mark on cap. Placing the long tail of
framing square against the spar cap edge, mark a line 90 to the spar, similar to BL 36. This will
now be BL 23.50, where inboard ribs „I‟ (fwd.) and „J‟ (aft) will be located. Starting at inboard
end of spar, stretch measuring tape toward outboard end. Align 36” on the measuring tape with
BL 36 on the spar cap and tape in place. Using framing square, mark lines 90 to spar centerline
at the following locations: BL 55.25, BL 74.50, BL 91.21, BL 117.34, BL 143.34, and BL 176.00
EXPRESS ASSEMBLY MANUAL SECTION 3 WING ASSEMBLY
©2000 Express Aircraft Co LLC Rev. 7/10 Page 3.010-18
at wing tip. Using a large square, extend these lines to forward and aft shearwebs, 90 to spar cap
centerline. Squaring off skin, draw lines from top of shearwebs down inside faces to skin. Locate
and mark BL 71.00 on spar cap and forward shearweb only (Landing light box). With all Butt
lines located and transferred to shearwebs, locate BL 76.00, 1.5” outboard of BL 74.50, on inside
face of forward and aft shearwebs. Squaring off skin, draw line from top of shearwebs down
inside faces to skin. Prep-sand forward and aft, inside shearweb faces, all the way from BL 76.00
to inboard end of part. This is for the 6“ x 60” uni-directional tapes and 7781 8” x 62” tapes.
Gently sand Q-Cell radii on inside shearwebs for Step 2.
B. Forward and aft shearweb laminates.
1) From BL 74.50, outboard to wing tip, apply (2) 3” tapes to inside radius of shearwebs 1.5” up
web and 1.5” onto skin.
2) From BL 75.00 to inboard end of shearwebs, apply 2 layers each, forward and aft, of 6” x 60”
uni-directional tape onto inside face of shearwebs to radius at wing skin. Finish each shearweb
with (1) layer of 7781 applied over entire uni-directional tape layers, overlapping radius 1.5” to
2” onto wing skin and extending approx. 1” beyond outboard end of uni-directional tape layers.
All laminates on inside of forward and aft shearwebs are now complete (Fig 10.14).
Fig. 10.14
EXPRESS ASSEMBLY MANUAL SECTION 3 WING ASSEMBLY
©2000 Express Aircraft Co LLC Rev. 7/10 Page 3.010-19
*Note: Outside Uni-Lams will be applied during close-out operation.
Allow to cure and then trim shearwebs before continuing.
Shearweb trimming widths:
Station Forward Aft
Outboard BL 176 4.30” 4.00”
Middle BL 91.21 5.00” 5.30”
Inboard BL 23.50 5.75” 6.30”
*Note: Because of differing wing sizes, ribs may need to be “custom fit” or sanded to fit.
This is completely normal. The tops of the ribs will trimmed down when the lower wing
skin is fitted to the wing assemblies.
EXPRESS ASSEMBLY MANUAL SECTION 3 WING ASSEMBLY
©2000 Express Aircraft Co LLC Rev. 7/10 Page 3.010-20
C. Rib location, fit, and installation.
1) Identify all spar cap locations and transfer lines to wing skin, spar and inside shearwebs for
rib locations.
*Note: Prior to positioning ribs in place, prep-sand ribs for tie-in laminates1 ½” up from areas of
contact or tie-in areas. Prep-sand skin, shearweb, under spar cap, and inside spar web face at all
locations, fore and aft.
Ribs are identified by letter and part number and are located as follows:
Butt line Rib Letter Part No. Location
BL 23.50 Rib I 111-12-013 Fwd.
Rib J 111-12-002 Aft
BL 36.00 Rib Q 111-12-016 Fwd.
Rib R 111-12-017 Aft
BL 55.25 Rib M 111-12-007 Fwd.
Rib O 111-12-007-1 Aft
BL 74.50 Rib A 111-12-003 Fwd.
Rib B 111-12-004 Aft
BL 91.12 Rib D 111-12-006 Fwd.
Rib D-1 (New) 111-12-006A Aft
BL 117.34 Rib E 111-12-008 Fwd.
Rib C 111-12-005 Aft
BL 143.34 Rib F 111-12-010 Fwd.
Rib F-1 (New) 111-12-010A Aft
BL 176.00 Rib G 111-12-011 Fwd.
Rib H 111-12-012 Aft
EXPRESS ASSEMBLY MANUAL SECTION 3 WING ASSEMBLY
©2000 Express Aircraft Co LLC Rev. 7/10 Page 3.010-21
2) Begin “dry-fitting”* ribs in place. Trim as necessary to fit ribs at marked locations, with ribs
centered on BL marks-snug, not tight. Open up or enlarge fuel passage vent holes as necessary.
Then seal foam-core that will be exposed to fuel by brushing resin and Q-Cell mixture onto
foam. Allow to soak in and then repeat.
Do not brush resin onto rib bond/contact areas on top and bottom, fore and aft locations on ribs.
Just coat the half-circle cutouts.
*Dry-fitting = Test fitting part in and out of position until desired shape is achieved.
3) Now remove ribs. Hot glue or dot contact spots on spar web, skin, and shearweb. Use square
to position rib 90 to skin and 90 to centerline of spar cap, centering on BL lines. Hold in
position with square until glue cools to leave stationary. When ready, mix Q-Cell and apply
radius to all ribs, inboard, outboard, fore, and aft. (Fig. 10.15)
*Note: It is preferable to use a resin, Cabosil, milled-fiber mixture on aft, inboard, main gear ribs
at BL 23.50 and BL 36.00. These ribs are stronger than the rest. They are made of 40 lb. foam
6 core 6 pre-lam and carry most of the load of your airplane.
Fig. 10.15 Apply Q-Cell with stir stick and use as a radius tool
*Shop Tip:
Brush lightly with acetone to smooth out before applying laminates.
EXPRESS ASSEMBLY MANUAL SECTION 3 WING ASSEMBLY
©2000 Express Aircraft Co LLC Rev. 7/10 Page 3.010-22
4) Begin applying tie-in laminates.
*Note: It is OK to begin applying tie-in laminates to ribs while Q-Cell is still in curing stage. Just
don‟t push, or force out, Q-Cell when working it. Otherwise light prep-sand of Q-Cell is
suggested after it has cured, prior to applying tie-in laminates.
5) Begin tie-in laminates on ribs. The following procedure is for all wing rib installations with
the exception of main landing gear ribs BL 23.50 and BL 36.00.
a) To apply laminates to ribs, apply 3“ rolled-up tapes, cutting lengths off rolls, as needed as
you go. Apply laminates to overlap rib and to bonding surfaces i.e. wing skin, shearweb, spar
web, and spar cap, 1.5” as shown in Fig. 10.16. Use continuous tapes on aft ribs.
For fuel cell ribs, cut laminates in between vent holes. Fig.10.17.
Fig. 10.16
Fig. 10.17
EXPRESS ASSEMBLY MANUAL SECTION 3 WING ASSEMBLY
©2000 Express Aircraft Co LLC Rev. 7/10 Page 3.010-23
b) Main landing gear rib installation.
For this procedure, the following parts will be required:
Part Number Location Qty
111-12-002 (Rib J) BL 23.50 1
111-12-016 (Rib R) BL 36.00 1
Prep-sand inboard and outboard sides of rib R and aft BL 36.00 (Face) and outboard side of rib J
BL 23.50. “Dry-fit” (Sand-to-Fit) at marked locations. Hot glue or dot contact spots on spar web,
skin, and shearweb. Use square to position rib 90 to skin and 90 to centerline of spar cap,
centering on BL lines. Hold in position with square until glue cools to leave stationary.
Note: You will construct rib R flange during Procedure 3.030A, Pg. 3.030-1.
c) Rib R, J, and I reinforcement laminates
Using resin, Cabosil, milled-fiber mixture, radius ribs R and J at all contact areas and cut full-size
plies as follows:
Note: Fabricate rib flange/cap prior to laminates. Section 3.030
Aft BL 36.00 (Rib R) 6 plies inboard
6 plies outboard
Aft BL 23.50 (Rib J) 6 plies outboard only
Fwd BL 23.50 (Rib I) 4 plies outboard only
* Shop Tip
Use meat packer paper or equiv. to position against rib and press into radii with fingers to
mark outline of rib. Then leave excess where required on overlap areas using paper
drawing as a template for cloth. See Figs. 10.18 and 10.19 below.
EXPRESS ASSEMBLY MANUAL SECTION 3 WING ASSEMBLY
©2000 Express Aircraft Co LLC Rev. 7/10 Page 3.010-24
Fig. 10.18
Fig. 10.19
EXPRESS ASSEMBLY MANUAL SECTION 3 WING ASSEMBLY
©2000 Express Aircraft Co LLC Rev. 7/10 Page 3.010-25
d) Applying tie-in laminates
Cut all laminates, stack and label where they go. Do one side at a time. Suggest using 100-150
grs. Resin at any one time. Gives you time to manipulate plies without resin curing too fast.
Yes!! This is a challenge----GOOD LUCK.
Take your time if necessary. After each successful laminate, you can wait until that ply is “tacky”
enough to not peel off. Then you can mix a new batch of resin and continue one-at-a-time to
achieve quality “lay-up”. Approximately 15-20 minutes Should suffice.
*BREAK TIME*
When finished with tie-in laminates, take a deep breath
and pat yourself and your helpers on the back!
This is a major step.
ENJOY!
EXPRESS ASSEMBLY MANUAL SECTION 3 WING ASSEMBLY
©2000 Express Aircraft Co LLC Rev. 7/10 Page 3.010-26
D. Hardpoint insert installation (Typical both wings).
1. Install forward shearweb hardpoints. There are (4) hardpoints (40 lb. ½” foam) on the
forward shearweb as follows:
Forward inboard BL 27.50 inboard to wing skin E.O.P. or more.
Approx. Size = 5.75”H x 9.0”W.
This is your forward shear tie, wing attach point.
Forward outboard BL 34.00 to BL 38.00.
Size = 5.5”H x 4.0”W.
This is your inboard aileron bellcrank location.
Forward outboard BL 89.00 to BL 93.00.
Size = 5.0”H x 4.0”W
This is your mid-wing aileron bellcrank location.
Forward outboard BL 143.00 to BL 149.50.
Size = 4.0”H x 6.5”
This is your outboard aileron bellcrank location.
Using a large square mark these BL lines onto top of shearweb. Next, using a square, mark on
forward face of forward shearweb, all above locations, 90 off skin. At BL mark, draw a line
with square from skin to top of shearweb. Mark an “X” between space of hardpoint for foam and
skin removal. (Fig. 10.20 and Fig. 10.21)
Fig. 10.20
EXPRESS ASSEMBLY MANUAL SECTION 3 WING ASSEMBLY
©2000 Express Aircraft Co LLC Rev. 7/10 Page 3.010-27
Fig. 10.21
a) To remove hardpoint cutout, use a cut-off wheel to cut most of the 2 plies only. Do not cut
thru shearwebs Remove fiberglass then use a scraper to remove the foam. Sand face to clean off
excess foam. Fit 40 lb. foam inserts into “pockets” formed by removal of foam and cover plies at
each location. (Fig. 10.22)
Fig. 10.22
EXPRESS ASSEMBLY MANUAL SECTION 3 WING ASSEMBLY
©2000 Express Aircraft Co LLC Rev. 7/10 Page 3.010-28
b) When inserts are fitted flush with cutout surface, mix-up resin, Cabosil, milled-fiber mixture
and apply to backside and edges of hardpoint. Do not apply mixture to forward surface of
hardpoint (This will be covered by close-out lams later). Press hardpoint into “pocket”, forcing
some “Mill-Cabo” to squeeze out. This is good, as it ensures that air bubbles are being squeezed
out from behind hardpoints (Air bubbles are a big NO-NO). Clamp in place, (2) clamps each
evenly spaced. Clean-up excess “squeeze-out” and move on to the next one. Allow to cure.
2) Install aft hardpoints. There are (5) hardpoints (40 lb. ½” foam) on the aft shearweb. Repeat
above steps D. 1), a) through b) for aft shearweb. Removing only backside face of aft shearweb
plies and foam at the following hardpoint locations:
Aft inboard E.O.P. of wing skin outboard to BL 27.50.
Size = 6.30”H x 9.0”W.
This is your aft shear tie attach point.
Aft outboard BL 68.00 to BL 73.00
Size = 5.5”H x 5.0”W.
This is your flap torque tube actuator bracket location.
Aft outboard BL 121.00 to BL 125.00
Size = 4.75”H x 4.0”W.
This is your inboard aileron hinge bracket point.
Aft outboard BL144.00 to 148.00
Size = 4.5”H x 4.0”W.
This is your middle aileron hinge bracket point.
Aft outboard BL 172.00 to BL 176.00
Size = 4.25”H x 4.0”W
This is your outboard aileron hinge bracket point.
Allow hardpoint inserts to cure.
It’s time for Ribs R and J flange installation.
Refer to Express wing assembly manual. Section 3, Procedure 3.030