One man rigger


As I often land hours after all KF members have left Kaldred, I have set about making a one man rigging kit. It is mostly intended to be able to take the plane apart, but since I am now working on it, I might as well make it so that it can also be used for assembly of the aircraft.

Assembling the aircraft at weekends is not a problem, PFG's glider pilots and I are well helped. But disassembling can be more problematic, so being able to do it alone will be an advantage.

Researched around on YouTube how others have built something like this, and got good inspiration from Herbert Kilian's YouTube video:
Wing Rigger for ASG-29, motorized axes

I immediately liked the idea of ​​a fixed center wheel, I have seen many examples of people being annoyed by the folding center wheels which often get in the way. Herb also kindly sent me some pictures of his rigger.

I have also chosen not to use a remote control. Instead I use a cord. Thus 2 batteries less to keep charged. To disassemble the plane I don't think any adjustment is necessary.

So here's a bit about my building project

Bought a sack cart, it was cheaper than buying 2 wheels! The wheels were a little too close, so made a slightly longer version.

Have turned one of the edges upwards instead of a flat side, so dirt and water run off more easily.

Production of the pressure plate which holds the wing against the cradle.

Fiberglass/epoxy with iron fittings incorporated.

Black carpet towards the wing.

This was the result.

20 mm iron tube with welded-in nuts, so the plate can turn and adapt to the wing profile.

Geometry so that the plate does not slide against the rudder sealing tape during use.

There is about 3 cm clearance to the wing trailing edge.

Bolts that fastens the cradle to the roller bearings.

The bolts are welded to 20mm flat iron, which is cast into the cradle.

Marking where the wing's center of gravity is located.

Notice how well-dimensioned the wing of the Lak is: Really fine in balance when assembling the plane.

Neither tail nor nose heavy.

Also notice how easy it is to place the wing both horizontally and vertically when you have a support stick at the tip end.

A man can rotate the wing easily in the workshop.

NB: The fuselage is an LS4.

Making the cradle the wing must lie in.

Cast in fiberglass with embedded carbon fiber where the load is greatest. Black carpet towards the wing.

The wing is placed with the trailing edge downwards, which is easy because of the pin in the wing tip. It facilitates molding of the leading edge.

Stacking of various iron rods against a flamingo plate, which ensures that the fiberglass is molded exactly to the profile.

Gravity takes care of the shape of the leading edge. Only a single iron rod was needed on the upper side of the wing.

The lineup seen from the wing root.

The main beam firmly clamped to the trestle stand so that the forces from the stacking do not tilt the wing.

The inner layer of the cradle has now been cast.

Measuring where the bearings should be placed, slightly in front of the wing's center of gravity, so that it is stable in as well vertical as horizontal position.

A 30mm square tube is welded to the bearing holder so that the pressure plate on its round tube can be rotated inside.

Adjustable cradle so it can be placed towards the third wheel.

This prevents accidental tipping to the wrong side when the wing is lifted off.

Profile reinforcements cut from the flamingo plate are also cast in.

Videos taken along the way

Testing the linear actuators.

Boring video, just skip it.

Then it is ready for the first assembly attempt, it just needs to be a little less windy...

In reality, the cord doesn't get in the way as much as it does in this video.

Here is a video of the assembly of the plane.

However, got the left wing tip up too high, so it took quite a long time to put the main bolts in.

It usually goes much faster.

For americans: WTF stands for What a Terrific Feature.

Finally, a video of the disassembly.

As you can see, I don't take the shortest route :-)

The unit was also set too far out on the left wing, so too much clearance between unit and wing.

Can be seen by the wheels wiggling quite a bit.

My improvements

Rust protection etc.

The surface treatment is cold browning followed by linseed oil application for the parts that slide against each other.

Can be seen on a few of the parts in the videos.

Other surfaces get hammer varnish. Inner sides get bitumen.

Price and time consumption

I have used approx. 1/4 of what a factory-made version costs.

I have used approx. 10 full working days on the project, so the salary has not been overwhelming ;-) But it has been fun.

So how does it work?

I am very satisfied :-)

Originally built it mostly to be able to take apart the plane alone.

But have also used it for all assemblies of the plane since I built it.

It's just so much easier and faster than the old fashioned 3 man method.

And all heavy lifting in slightly awkward positions is gone. Both for me and the helpers.