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Zenith CruZer & Sonex Logs
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Date: 3-28-2009
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Number of Hours: 0.00
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Manual Reference: n/a
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Brief Description: Wing Cradle
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Well, technically, I didn't work any metal today, but I was still wrapped up with things Sonex.
I had previously made a wing cradle out of Sch 40 PVC pipe. This worked "ok" for one wing, but as I was now ready for the aft fuselage skins, I needed the workbench (the other wing has resided there since completion).
I decided to build the Tony Bingelis wing cradle, the plans for which can be found on the EAA website. I made two major modifications: I increased the length from 5' to 6', and I reduced the width from 36" to 30", the latter done mostly to allow my wife to continue parking on "her" side of the garage.
All in all, I was impressed. I had most of the wood already in possession; only had to buy 3 sections of 2x4. For the gusset material I just used the MDF board used on the prefab spar crate, cut to size. Fortunately, Harbor Freight had a sale on small swivel casters, so I made out for far less $$$ than the PVC cost me for the first cradle, without casters.
I was amazed at how rigid and strong this cradle turned out to be. Unfortunately, I discovered why I should have stayed with the 36" width - when the wings are in the carpet slings, they naturally want to push outward. At the narrower width, they push up against the gussets. I was able to shorten the carpet a bit, which raised the wings higher, and also installed some foam padding, thanks to a sacrificial swimming pool "noodle" (visible in pic 1 below).
Two other quick notes: with the PVC cradle, I was becoming more concerned that a section might come unglued, resulting in a wing crash on the cement floor. That would be Bad. Second, I bought the carpet straps at Home Depot. The clerk just couldn't resist asking why I only needed a 1' x 12' section of carpet. He started asking quite a few questions when I told him!
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