Champ Wing drag wires

E

Eric Brown

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Apr 7, 2021
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167
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Belle Plaine, Mn
I have an interesting disparity. I have 16 wing drag wires. The number that is required to do both wings. However, they are of multiple diameters and lengths. According to wing drawing 7-774, and all of the wood spar models parts manuals, I should have (2) 1-2595-1, (4) 1-2595-2 and (2) 1-2527-2 wires per wing. The only dimensional info I can find is on the Wag-Aero and Spruce sights, of which only 2 of my wires match. My 2 wing set wires are as follows ...................

........ (2) .190" x 52.75" with 1.5" threaded ends.
.........(2) .168" x 52.75" " " "
........ (11) .190" x 49" " " "
....... (1) .168" x 48.8" " " "
.........(2) .190" x 48" with 1.5" and 3/4" threaded ends.

Does anyone have a dimensional reference for each required wire ?
 
I was just working on these tie rods this past fall on my 7AC.
I'm no expert so I may be incorrect on some things.
I always thought the wires were all the same diameter. 6 of the wires are all one length and 2 are longer. the two longer ones go in bay 2, working from the root. That bay has the wires passing through spars on both ends, the other 3 bays have one end attached to a fitting and don't pass through the spar, the other ends pass through. The ends aft of the rear spar shouldn't have more than 1/4" extending beyond the washer and two jam nuts, so that there's no interference with the aileron cable.
I haven't miked the dia of the wires because I thought they were the same. I have a mix of some old ones and new ones from Safe Air in the wing now.IMG_1629 (1024x683).webp
 
I'm beginning to wonder if I've got a mixed batch of wires from other airplanes. The .190" dia. and .168" dia. both use the 3/16 - 28 nut.
 
Looking at both factory drawings for 1-2527 and 1-2595 show that 2595 is an assembly drawing with no real dimensions other than thread length beyond the nut and clevis fittting, which make no real sense to me. It shows 1/4" and 7/8".
Drawing 2527 shows a diameter of the rod itself as .167, + or - .010.
The two lengths are 48 15/16" and 52 13/16". The numbers required per plane don't make a lot of sense to me either.
Obviously the correct dia is cricital, but the overall length needs to be enough to extend into the fittings, with not too much past the rear spar like I said. Any extra in front of the spar wouldn't be that critical.
I was hoping that someone else would respond with more info than what little I have.
 
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Interesting that both Wag-Aero and Spruce indicate that wire 1-2527-2 diameter as .190" as opposed to the drawing dimension of .167". I was unable to locate any of the wire drawings during my research.
 
I have a CD from the National Aeronca Assoc which has copies of most of the original drawings from Aeronca. I was looking at that factory drawing to get those dimensions I gave you.
I'm assuming that the dia of the wires were increased on later models, of course the size of the holes in the spar would have to be increased too.
 
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