Home' Aerogram : Aerogram 2009 4 December Contents Aerogram December 2009
A Rigger’s Notebook
Continuing with Cecil Cuss’s notes as a Royal Flying Corps trainee aircraft rigger.
Transcribed by his son-in-law, Bruce Thomas.
I’ve rearranged some of the text for clarity (Ed.)
Aerogram December 2009
Instructions for Wire Splicing
Note whether wire has a right or a left hand twist before
starting and allow9” to 12” extra wire.
Wire should be served neatly with waxed twine, before
fixing galvanized thimble. After this the thimble is ready to
be fixed on the wire by means of waxed thread in figure
eights, find the heart and it’s proper lay and tuck under
three strands. 1
tuck, take No1 wire, tuck it under
second to the right of the place where the heart went in.
No2, 3, 4 following on the same from the right to left. No5
tuck under two strands. No6 tuck under the first of the
two that No5 went under.
Special care must be taken to pull the first tuck well down
tightly and beat it down with a mallet.
2nd tuck, take strand to the right of where the heart comes
through and tuck it over 1 and under 1. Repeat same until
the six strands have been tucked, always working from
right to left, next pull all down tightly and beat well.
3rd and 4th tuck. Repeat No2 5th tuck, take strand to the
right of heart, and every other one and under 2 pull all
strands down tightly and beat splice thoroughly.
Next cut off all strands and serve with waxed twine. If left
hand wire, splice in same manner only reverse operations.
Great care should be taken to prevent any kinks from
appearing in the wire.
NB. All cable wire both before and after splicing must be
stretched before putting into a machine.
Special note on piano wire.
Piano wire to be used should not have been bent
previously and must be free from all kinks.
Wire should always be cleaned before being worked into a
Care should be taken when wire requires an eye turned on
both ends, that two ferrules are put on the wire before the
second eye is turned.
Ferrules employed in connection with the eyes of piano
wire must be made of steel; copper ferrules must never be
used. Care must be exercised in turning eyes in piano
wire, and should the eyes be turned and the radius of the
eye is not correct, it is liable to elongate and allow the
structure to fall out of alignment.
Trueing up Fuselages
The datum lines on all side struts of fuselage are to be
level and coincide with chalk lines stretched between A
and C. Front engine bearer plates are to be plumb inside
view and are to be square with axis of fuselage in plan.
Centre to centre of engine bearer plates are exactly level.
Rudderposts to be perfectly plumb both ways.
Order of truing up
Internal sections 2nd Sides 3rd Bottom 4th To p
Place fuselage on trestles at A B and C and mark down
8”on all struts from top of top longeron for datum line. Fix
section straightedges by clamps laterally across fuselage,
on struts A and C, and stretch chalk line taut between
these on each side of fuselage.
Pack up trestle A until straightedge is laterally level.
Cramp along side straightedge on side of fuselage to
coincide with the chalk lines, irrespective of marks on
struts and pack up trestle C until the datum line and
straight edge are level taking care that the section
straight edge over trestle C is laterally level also.
Trueing Internal Sections
Start with section supported by trestles, and adjust
bracing wire until diagonals are exactly equal. Adjust
each section in turn in the same manner
Trueing Side Sections
Trammel front bay so that engine bearer plates are
square to top longerons, then start from front bay and
adjust all the trueing wires until all the marks on the side
struts of fuselage exactly coincide with the datum line
stretched along fuselage from A toC. Work
Both sides if the fuselage together from the forward bay
to rear, keeping struts and sternposts plumb.
Trueing Bottom Sections
Mark exact centres on all bottom struts of fuselage.
Trammel bay where wing socket fittings are secured by
checking diagonals, which must be exactly equal. Stretch
a line from centres of struts of line stretched along
fuselage from A to B. Work both sides of fuselage
together from forward bay to rear keeping side struts and
sternpost perfectly plumb.
Trueing Top Sections
Mark exact centre of all top struts of fuselage and stretch
a line from centre of front strut to centre of rear strut.
Adjust bracing wires until the centers of all other struts
coincide exactly with the line.
TYPE No.2 (example Camel)
Machine is in the flying position when the top longerons
from strut 1 to 4 are level longitudinally and laterally, and
the marked points on struts exactly agree with the chalk
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