Wing Assembly Jig

To achieve the highest possible precision during wing construction, the assembly is carried out using a specialised jig. This structure needs to be not only dimensionally accurate but also extremely resistant to distortion. In the original aircraft, simple wooden trestles were used for this purpose. We, however, opted for a far more robust solution: a custom-made frame built from steel tubing, capable of supporting the entire wing throughout the assembly process.

This was no small task – several-metre-long steel profiles with a diameter of 80 mm had to be positioned with millimetre accuracy and welded together without any warping.

Fortunately, once again, luck was on our side. The company Herzog Metallbau, based in Ermatingen, generously offered to supply the materials and take on the challenging welding work as well. This support was invaluable, and we are extremely grateful for it.

No sooner said than done: within just two days, three main structural elements of the jig were fabricated in their workshop in Ermatingen – using around 300 kg of steel tubing. Thanks to the exceptional skill of the welder – and with my help as an assistant – the jig was ready in remarkably short time.

Next came the transport to Bleienbach, where the components were assembled into a complete framework for the entire wing.

With the jig now in place, the actual wing assembly can finally begin.

Anschließend folgte der Transport nach Bleienbach und der Zusammenbau zu einem vollständigen Montagegerüst für den gesamten Flügel.

Jetzt kann der eigentliche Zusammenbau des Flügels beginnen.

Keine einfache Aufgabe – denn meterlange Stahlprofile mit einem Durchmesser von 80 mm müssen millimetergenau positioniert und verzugsfrei verschweißt werden.