Chapter 17, Annex AC FUSELAGE AND BOTTOM WING ASSEMBLY LINE

Director Cadets 3, 2007, Ottawa, ON: Department of National Defence

Figure AC-1  Fuselage and Bottom Wing Assembly Line

For each aluminum model biplane to be constructed:

1.Combine parts F-1, F-2, B-1 and B-2 with staples to make a full fuselage (Figure 17AC-2).

2.Slide Template No. 1 over full fuselage (Figure 17AC-3).

3.Use push-pins to create holes in fuselage through Template No. 1.

4.Trace, but do not cut, the openings for the cockpit and windshield.

5.Remove Template No. 1 from fuselage (to stock for Drill Station).

6.Insert bottom wing spars in fuselage holes A and B (spars/fuselage from stock).

7.Tape cardboard parts BWC to bottom wing spars (BWC and spars from stock) (Figure 17AC-4).

8.Tape or glue cardboard part BWAS to top of BWC (BWAS/BWC from stock).

9.Repeat Steps 7. and 8. for other wing.

10.Wrap top of left bottom wing with pre-bent aluminum panel (from stock) (Figure 17AC-5).

11.Wrap top of right bottom wing with pre-bent aluminum panel (Figure 17AC-6) (from stock).

12.Insert under-wing panel (dimensions 2-5/8 inch by 8-1/8 inch) into left wing (Figure 17AC-7).

13.Insert under-wing panel (dimensions 2-5/8 inch by 8-1/8 inch) into right wing (Figure 17AC-7).

14.Staple panels (three staples) at left wing tip (Figure 17AC-8).

15.Staple panels (three staples) at right wing tip (Figure 17AC-8).

16.Trim wing tips to desired shape.

17.Make two slits for the windshield (Figure 17AC-9).

18.Trim cockpit aluminum to avoid blocking pilot hole in F-1 (Figure 17AC-10).

19.Carefully turn biplane upside down.

20.Split cockpit back in half so it will fold down and place wire insulation on cockpit edging (Figure 17AC-11).

21.Turn the Wing Bolt Hole Placement Template (WBHPT) upside down also, and apply WBHPT to the underside of the bottom wing Figure 17AC-12).

22.With a push-pin, make holes for four outer bolts in the bottom wing near the wing tips. Do not make holes near the fuselage (fuselage with bottom wing to stock).

D. P. Mathis, Building the B.C. Air Originals Biplane, B.C. Air Originals (p. 6)

Figure AC-2  Fuselage Assembly

Building the B.C. Air Originals Biplane, by D. P. Mathis, B.C. Air Originals (p. 6)

Figure AC-3  Fuselage With Clear Mylar Template Placed Around

D. P. Mathis, Building the B.C. Air Originals Biplane, B.C. Air Originals (p. 7)

Figure AC-4  Getting Its Wings

D. P. Mathis, Building the B.C. Air Originals Biplane, B.C. Air Originals (p. 7)

Figure AC-5  Cladding the Wings

D. P. Mathis, Building the B.C. Air Originals Biplane, B.C. Air Originals (p. 8)

Figure AC-6  Under the Wings

D. P. Mathis, Building the B.C. Air Originals Biplane, B.C. Air Originals (p. 8)

Figure AC-7  Cladding the Under-wing

D. P. Mathis, Building the B.C. Air Originals Biplane, B.C. Air Originals (p. 9)

Figure AC-8  Securing the Wing Tip

D. P. Mathis, Building the B.C. Air Originals Biplane, B.C. Air Originals (p. 9)

Figure AC-9  Roughing the Cockpit and Windscreen

D. P. Mathis, Building the B.C. Air Originals Biplane, B.C. Air Originals (p. 10)

Figure AC-10  Clearing the Centre Line

D. P. Mathis, Building the B.C. Air Originals Biplane, B.C. Air Originals (p. 10)

Figure AC-11  Opening and Trimming the Cockpit

D. P. Mathis, Building the B.C. Air Originals Biplane, B.C. Air Originals (p. 12)

Figure AC-12  Wing Bolt Hole Placement Template (WBHPT)