Work Bench Construction

All of the major airplane airframe components must be built meticulously straight and symmetrical. This includes both wings, the fuselage, the horizontal stabilizer, the vertical stabilizer, and control surfaces such as flaps, ailerons, rudder, and elevators. The only way to build these components as precise as they need to be is to use jigs to hold them in alignment as they are being built. Lancair jigs are placed and aligned on top of level workbenches.

The picture below shows one of 4 workbenches that I built for this project. These tables will hold jigs that help me make sure that specific airframe components are built correctly. This helps make sure that in the end, the plane I am building, for example, flies straight when I want it to. Given the function these tables serve, they need to be level, square, rigid, and sturdy.

The primary reason I needed to build 4 of them was due to the fact that each wing is a little over 16 feet long. Each wing will require 2 tables butted end to end to form one 16 foot workbench per wing.

Builder Note:

Workbench Height

The construction manual calls for 24” legs. With 24” workbench legs, the jig will place the airfoil cord line at Cradle BL 25.5 ( wing root end ) approx. 45.5” above the ground. This will also place the leading edge cord line at Cradle BL 204 ( wing tip end ) 33” above the ground. On the inboard end, I found the wing higher than I would like when accessing anything between the 25% and 50% cord area. This was especially true when I was spreading Hysol for final wing closing. I found that I needed a step stool to be high enough to reach that center area comfortably. I am 5’ 10”, so this may be even more of an issues for shorter individuals. Making these tables shorter would make it easier to work on the inboard end of the wing. I would think that 18” legs would resolve this issue. Lower than 18” would likely put the outboard end of the wing too low to work on comfortably.

The process I used in constructing the workbenches was somewhat different as well. I found it easier to square the legs by building each long side flat on a work table. Pictured below is one completed workbench side.

The main structure board for the top perimeter of the table is made of a 2x6 board. Inside of the 2x6 board is a 2x4 that helps hold the legs in place and provides a stop for the 45 degree leg supports. These supports are critical for making the table rigid. The picture below shows that the vertical 2x4 legs extend to the top of the 2x6. Assuming that you miter your cuts accurately, the method I used in constructing these tables makes if very fast and easy to keep parts square.

Final assembly was done once I finished both sides and cut the boards that join the two sides. Actually, once I complete the first table, I made all of the cuts for the rest of the tables. Then I assembled the sides, and then performed final assembly for each table. The last 3 tables took about as much time as it took to build the first table thanks to the mass production process that I used for the remaining 3 tables. Both sides would actually free stand which made it easier to complete final assembly ( as pictured below ). Final assembly was done with the table top down on the ground.

I used 2.5” galvanized exterior screws. When attaching one board to another with these screws, I found it easier to pre drill the board that the screw started in. As the screw entered the second board, it pulled the two boards tightly together. If I did not pre drill, the two boards would get pushed apart as the screw began to enter the second board.

Builder Note:

Table Hardware

I originally constructed my tables using 2.5” galvanized exterior screws. After reading some discussions on the Lancair Mail List, some Lancair builders reported that these type of screws were insufficient when you consider that at certain stages ( such as wing closure ) you need to put a substantial amount of weight on the wings. I have replaced many of the exterior screws with #14x3” wood screws. After converting one table, I compared its rigidity to one of the tables I had not yet converted. It was noticeably more rigid than the others. Pre-drilling holes for these screws is essential, otherwise wood splits are probable. I am pre-drilling 2.25” holes with a 3/16” drill bit.

As with the sides, I had an inner horizontal 2x4 to help provide stops for the 45 degree leg supports. These supports helped make sure that both sides were square.

Initially I was going to leave the tops of the workbenches open. Given all of the wood I salvaged from the crates, I have closed the tops with crate plywood. This saved the cost of buying the plywood.

If you are interested in building your workbenches like I did, here is a list of parts, and measurements for each table.

(6) 2”x4” Legs
Each cut to 18” to 24” depending on desired height of the tables
(2) 2”x6”x36” Table End Boards
(2) 2”x4” Table End Boards
Cut to the length of (36” - the thickness of two 2”x4” boards). I cut mine to fit in the space that each board was going into.
(2) 2”x6”x8’ Table Side Boards
(4) 2”x4” Table Side Boards
Cut to fit between the side legs. I cut mine to fit in the space that each board was going into.
(12) 2”x4”x20” 45 Degree Leg Supports
Two 45 Degree Leg Supports Per Leg,
Each end will needed to be 45 degree miter cut,
The long side can be 20”, but this length can be adjusted as desired.
(24) #14-3” Screws
I used 2 screws per leg to fasten them to the side 2”x6” boards. I also used 2 screws per horizontal 2”x4” board that was screwed into the 2”x6” boards. I pre drilled approximately 75% of the screw length for these screws with a 3/16 drill bit.
(1 Box) 2.5” Galvanized Exterior Screws (GES)
The remainder of the screws I used were 2.5” GES. I used these smaller screws in places where they would not be supporting the full load of the wings and weights, but just holding the supporting board in place. I pre drilled holes for the first board that the screw went into, but not the second board.

Also, EAA Chapter 1000 from Edward AFB in CA have the plans for what looks like a nice work table. Some adjustments will be need for Lancair ES wing purposes, but most of the plans are applicable. Given the level of technical expertise in that chapter, it is worthwhile to read some of the other articles they have posted there.

If you have further questions, send your request to DAP@Lancair-ES.com.

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