Champ Assembling a Champ

[Bob Turner]

Just posted this on the Aeronca forum, but figured there may be 7AC folks lurking here as well . . .

Just started assembly of a 7AC (apparently a 7DC, but not sure I know the difference yet).

There is a document on the workbench that the owners used to order new bolts. It clearly shows the outboard strut attach bolts as (front to back) AN6-24 and AN 5-15 rear.

These are so clearly incorrect that it boggles the mind - it looks to me that the proper bolts are AN5-16 and AN5-25.

Do I have a bogus document? I will get title and source today.

I might have a question about engine mounting - on the J3 it is quite specific about fiber washers under metal washers. Is that the same for Aeroncas?

 

[Bob Turner]

Slowly getting there. Wings and ailerons are on - darn near every bolt is different, and the drawings do have flaws.
Tomorrow I start the tail feathers - there are two fat aluminum pulley-like affairs, a flimsy U-shape bracket, and a turnbuckle barrel in a bag. I am truly hoping they are part of the trim system. If I don't figure it out manana, I will post a photo.

 

[Bob Turner]

Talking to myself, I guess. Really struggling with the bolts holding the turnbuckles to the elevator, especiaally the upper one. This afternoon I grabbed a young, talented mechanic: "Here, you try!"
He couldn't get it either.
Tonight I will build a special tool - a bullet bolt on the end of a brass extrusion.
But it has to be the same as the Decathlon/Citabria? I just cannot get my fingers in there, even with the down-stop removed and the inner hinge pins out.
Surely somebody around here has assembled a Champ?

 

[Hiperbiper]

Bob, my front strut-to-spar was an AN6-...very tight fit and the front and rear brackets have to be lined up perfectly or no amount of wiggling will get that bolt thru.
As for the elevator horn turnbuckle it's a standard fit and should pose no problem if the cables have slack in them...
Be sure you use the proper bolts,washers and nuts on both the up and down cable turnbuckle attachment; too long a bolt will catch on the frame.

Sorry I didn't see this post before...

Chris

 

[Bob Turner]

Thanks. Today I discovered the secret - you partially insert the right elevator, after removing the "down-stop" bolt. Then you can easily get the clevis bolts in. Once that is done, put nails in the hinges, mount the left side, hook up the trim, and all is happiness!
Yay!

I should mention that this bird takes 1/4" clevis bolts on the elevator cables. The book says 3/16". I have the feeling that Champs are all over the map, bolt-size wise. Front strut was AN-5, rear was AN-6. Shows opposite on the Aeronca drawing.