Making new spars for a 7BCM

David Johnson · Post by **David Johnson** » Wed Feb 11, 2009 13:01

Robert, no hole in the little rib. You will have to drill the spar though. Anyone have a photo handy? David J.

s35pilot · Post by **s35pilot** » Wed Feb 11, 2009 18:01

Here are a few pic's of the brace installation.

Robert Henley · Post by **Robert Henley** » Wed Feb 11, 2009 20:57

Tim

Thanks so much for taking the time to take the pictures and posting them today! It is just what I needed so I know what to do next.

This forum is really something else. It sure helps to get sage advice from those who "travelled" before me down the path of Champ restoration.

Regards

Robert

Post by **joea** » Thu Feb 12, 2009 00:08

Robert,

Nothing like a good photograph to clear things up, and Tim and David's work is excellent so glad to see it!

Joe A

s35pilot · Post by **s35pilot** » Thu Feb 12, 2009 00:13

Robert, you are welcome.....anytime!

David Johnson · Post by **David Johnson** » Thu Feb 12, 2009 08:24

Joe, slight correction. This is Tim's work. Much, much better looking than mine! Me a tractor style mechanic. Fill out paperwork with crayon, just like Tater. David J.

Post by **joea** » Thu Feb 12, 2009 10:06

But David, the colors are so nice!

Nathan K. Hammond · Post by **Nathan K. Hammond** » Thu Feb 12, 2009 12:29

And crayons taste good.

nkh

Post by **joea** » Thu Feb 12, 2009 13:14

Not surprised that 'tater would say that! Course I ate a few as a kid as well, and look how I turned out!

s35pilot · Post by **s35pilot** » Sun Feb 15, 2009 11:34

I wanted to install drag wire anti-chaffing material where the drag wires intersect, I picked up some 1/4" vinyl tubing from Home depot, the inside dia. was the perfect size for the drag wires. I cut several pieces 3" long then split them down the center (looking back, I wish, I would have thought of sliding them over the drag wires before assembly) but, this worked out well, then I used electrical/avionics waxed lacing tape to tie them together.

Safety wired compression strut bolts at the lift struts, in preperation to install leading edges.

I used Cosmoline on all the exposed drag wire threads to protect from moisture. (It's hard to see)

N3840E · Post by **N3840E** » Sun Feb 15, 2009 21:04

I'm sure others will agree, it's going to be a shame to cover up all that beautiful work. I always look forward to your progress posts.

s35pilot · Post by **s35pilot** » Mon Feb 16, 2009 09:47

Kevin, thank you..........this website is why, I decided to start this blog, I have learned a lot from reading all the other blogs as well!

jc pacquin · Post by **jc pacquin** » Mon Feb 16, 2009 20:55

Always amazed to see such nice work, after some aircraft rebuilds I've seen! oskosh type stuff, shame to cover it up JCP

Post by **joea** » Thu Apr 09, 2009 11:28

Hey Tim,

Its April and I know that you have not been letting the project sit. How about some new photos???

Also, have just made this thread a "Sticky" so that it stays at the top of the catagory. Just too much good information here and want it to be available to everyone who is looking for information.

Joe

s35pilot · Post by **s35pilot** » Fri Apr 24, 2009 00:20

Hi All, well, a lot has happened since my last post, with the economy the way it is and business slowing down, I decided to rent my a hangar out and move the project home. I have been working on the wings, just been a little here and there. I just logged on and saw Joe request so, here we go.

I completed the 2 piece leading edge from Wag Aero (on both wings), boy, that's the way to go. I used Nathan's suggestion about heating the skin up in the sun and that really helps, you also notice that I followed several other method using the straps and dowels, they came out real nice.

I had to change the screwing pattern just a bit to allow screws to attach in new holes with using the old and new ribs, but this allowed me to have the same pattern in all the ribs.

This is the sheet metal tip that wag Aero sells (it does not fit well at all) so, I decided to make my own.

I used a piece of light cardboard and made a template.

I made this piece for the tip from the template, This is the left wing tip, I have only completed the right tip so far.

Here you can see the difference between the two.

This is the right tip complete, I had to shrink the front edge and I used a 2 part filler to smooth it out.

My buddy gave me these nav lights and I came up with this way to install them, I used 090. steel to fabricate these pieces and tapped the outside pieces for 8/32 screws, drilled the tip bows attached them and then welded the to the bows, I going to try to use them for attaching a bracket for a wing rotater a friend of mine has when it comes time for covering (which I'm hoping to start in a few weeks).

I used snap bushing (from Aircraft Spruce) and 3/8 vinyl tubing (Home Depot) to install a conduit for the nav wires, I know this is probably over kill but, that's just how I like to do things. Well, That it for now, I will post more as I continue.

National Aeronca Association Bulletin Board

Making new spars for a 7BCM

great work!