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1. Lay three spreader bars on a flat surface, and fit the fuselage sides into them UPSIDE DOWN
as shown in Figure 1-5. Add the two remaining bars to the "Top" with the rear one at Station
5.
2. Square the sides and the front end as shown, and after a double-check of the nose from the
opposite side to be SURE that it is square, tack on two cross-strips of wood aft of Station 6 to
assure the rigidity of the structure.
3. Build up wing support Stations 3 and 5 according to Steps A through D of Figure 1-6. The
curves for the plywood faces of Step D can be marked to size by notching the straight sections
to fit and then penciling around the corner bows. Be sure to varnish the areas inside the
structure before putting on the second piece of plywood.
4. Landing gear support Stations 2 and 4 are built up the same way except that corner bows are
not used. Do not build in Station 2 until after the firewall is mounted.
5. The shapes and locations of the various 3/h" plywood filler blocks that anchor the Station 2
through 5 cross members to the lower double-longeron structure are determined from the
details of Figure 1-7 as keyed to Figure 1-1. The dimensions are not critical, but should not be
less than shown. Note that the blocks at wing support Stations 3 and 5 are notched out 3/16"
to allow the wing fittings to slip through. The holes in the rear blocks at Station 3 for the
aileron push rod are a bit under-size at this stage deliberately.
6. Glue the blocks to the outer plywood skin after pressing them tightly against the plywood of
the cross-members per Step E of Figure 1-6.
7. Cut and fit 1/8" plywood to form an inner covering for the double lower longeron structure
per Step F of Figure 1-6. Don't forget to varnish the insides before putting on the plywood,
and then drill a vent hole at the bottom of each closed area. It is best to drill the hole in the
plywood before you put it on.
NOTE
The work of Steps 3 through 7, above, results in Box Structure, which should be
inspected and approved by an FAA inspector before being closed up. He may not
insist on it for this particular piece of structure, but it is YOU responsibility to notify
him. Show him the drawings way ahead of time, and you might not be held up at this
point by having to wait for his approval.
[The above note is included for historical purposes. The FAA no longer requires these kinds of
inspections. RJW]
8. Mark the location of the wing spar pin holes on Stations 3 and 5 per the cross-section views of
Figure 1-9. They can be drilled at this time, but it is a good idea to wait and see if the wings
line up properly.
9. With Stations 3 through 5 in and anchored, the structure is now sufficiently rigid to allow
removal of the spreader bars so that it can be turned over for working at more convenient
angles.
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