Boeing 737. Boeing 737NG Nose Sectional. Assembly Instructions

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Linda Potter
6 years ago
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1 Boeing 737 NG Boeing 737NG Nose Sectional Assembly Instructions

2 Before you begin Congratulations on the purchase of your new Flight Deck Solutions Boeing 737NG Cockpit Shell. The purpose of this document is to provide guidance during the assembly of your new shell. By no means is this document meant to imply that you must build your shell as outlined below. In fact, we encourage you to assemble the pieces using a method you feel comfortable with. Please let us know if you find any errors within this document, or have suggestions that will help improve the build process. Finally, have fun with this! What you ll need to get started 100+ L Brackets [LB] (2 x 1.5 x 1.5 ) 40 Flat metal plate [FMP] (5 x 2 ) 2 Flat aluminium strip [FAS] (24 x 1.25 ) x 3/4 bolts nuts x 3/8 wood screws Robertson or Phillips screwdriver Hammer Socket wrench set or pliers Metal cutters Drill with 11/64 metal & wood bit Space to accommodate assembly (roughly 10ft by 10ft is ideal) Approximately 24 total hours to build your shell. 1

Time to build 1. After unpacking your parts, separate all pieces by the following categories; Pair up labels Separate shell sections by upper (ex. RIB06U), lower (ex.

3 Time to build 1. After unpacking your parts, separate all pieces by the following categories; Pair up labels Separate shell sections by upper (ex. RIB06U), lower (ex. RIB01L & R), and window frame (ex. WF-04) pieces. 2. Attach the two G4 base pieces together with 4 nuts & bolts and a FMP. Continue attaching the two F3 base pieces together with 4 nuts & bolts and a FMP. Drilling may be required to line up the FMP with the predrilled holes on the wood pieces. 3. Attach RIB01L and RIB01R together with 4 nuts & bolts and 2 FMP (one on each side). Continue connecting Rib02L to RIB02R and RIB03L to RIB03L and Rib03R to RIB03R using the same method. 4. At this point, you can start laying out the base pieces with G4 on the First Officer [F/O] side and F3 on the Captain [CAPT] side. Ensure that the ends with 2 slots closest together face the back of the cockpit and the open side of the slots face outward. 5. Take the assembled RIB01 piece and insert it into the front most slots. Using 4 x LB s and wood screws, secure Rib01 to the G4 and F3 base. While sitting inside of the shell, ensure RIB01L is on the CAPT side, and RIB01R is on the F/O side. 6. Continue attaching RIB02(left & right) through to RIB07(left & right) to the G4 and F3 base using the same methodology as step #5. See figure #1. Figure #1 2

4 7. Now for the window frame. Locate both WF-15 pieces and lay them across the top of RIB02, RIB03, and RIB04 with similar WF-15 ends connected on RIB02. NOTE: Each end of WF-15 has a slightly different angle. It is important that you attach the front most pieces (resting on top of RIB02) so that the opposite ends of WF-15 are CLOSEST together. You should know that you have the correct angle, because it will easily lie across RIB02, RIB03, and RIB04. Connect the front most end of WF-15 with 4 nuts & bolts and a FMP. See figure #2 Using numerous wood screws, attach WF-15 to RIB02, RIB03, and RIB04 using LB s. See figure #2 8. Locate both WF-04 pieces and place them together (back to back). Using LB s and 6 nuts & bolts, mount both WF-04 s to the centre point of WF-15. Drilling will be required to secure all pieces together. See figure #2 Figure #2 9. Locate both WF-01 pieces and position them on top of WF-04. NOTE: Each end of WF-01 has a slightly different angle. It is important that you attach the front ends (resting on top of WF- 04) so that the opposite rear ends of WF-01 are CLOSEST together. You should know that you have the correct angle, because it will be parallel to WF-15. 3

5 Connect the front most end of WF-01 with 4 nuts & bolts and a FMP. See figure #3 Using 6 nuts & bolts, attach WF-01 to WF-04 using LB s. See figure #3 Figure #3 10. Using LB s and wood screws, position WF-05 at the end of WF-15 / WF-01 and on top of RIB04. You may be required to bend the LB s with a hammer to get the correct angle. See figure #4 11. Locate both WF-16 pieces and connect them to RIB04 and RIB05 using woodscrews and LB s. See figure #4 12. Attach WF-02 to WF05 with LB s and wood screws. You may need to find some scrap wood to prop up the one end while completing this. See figure #4 13. Using LB s and wood screws, position WF-06 at the end of WF-16 / WF-02 and on top of RIB05. You may be required to bend the LB s with a hammer to get the correct angle. See figure #4 14. Locate both WF-17 pieces and connect them to RIB05, RIB06, and RIB07 using woodscrews and LB s. See figure #4 15. Attach WF-03 to WF06 with LB s and wood screws. You may need to find some scrap wood to prop up the one end while completing this. See figure #4 4

16. Using LB s and wood screws, position WF-07 at the end of WF-17 / WF-03 and on top of RIB07. You may be required to bend the LB s with a hammer to get the correct angle. See figure #4 Figure #4 17.

6 16. Using LB s and wood screws, position WF-07 at the end of WF-17 / WF-03 and on top of RIB07. You may be required to bend the LB s with a hammer to get the correct angle. See figure #4 Figure #4 17. As you did previously with the lower RIB pieces, attach RIB01U and RIB01U together with 4 nuts & bolts and 2 FMP (one on each side). Continue connecting RIB02U to RIB02U, RIB04U to RIB04U, RIB05U to RIB05U, RIB07U to RIB07U, RIB08U to RIB08U, and RIB09U to RIB09U using the same method. 18. Completing the upper windows can be challenging, so ensure you are well rested for the challenge! Using 6 wood screws and 1 FMP, connect WF-10 and WF-11 together with the FMP on top. To ensure you are doing it correctly, position the angled ends of WF-10 and WF- 11 together with WF-10 pointed towards the middle of the shell. Continue the same steps for the WF-10 and WF-11 on the opposite side of the shell. 19. Using 6 wood screws and 1 FMP, connect WF-08 and WF-09 together with the FMP on top. To ensure you are doing it correctly, position the angled ends of WF-08 and WF-09 together with WF-08 pointed towards the middle of the shell. Continue the same steps for the WF- 08 and WF-09 on the opposite side of the shell. 20. Find RIB-06U and attach them on both sides of the shell with LB s and wood screws as outlined in Figure #5. The end of RIB-06U with the greatest angle should be placed directly overtop WF Find RIB-03U and attach them on both sides of the shell with LB s and wood screws as outlined in Figure #5. The end of RIB-03U with the 90 5

7 degree angle should be placed directly overtop WF-05. You will need to bend the LB s to obtain the correct angle. Figure #5 (outside view) 22. Using nuts & bolts and LB s, take the connected WF-10 and WF-11 piece and attach it to RIB-06U and RIB-03U. You will need to bend WF-10 and WF-11 at the seam, as well as adjusting RIB-03U and RIB- 06U to fit everything properly. See figure #5 23. Using LB s and nuts & bolts, attach WF-12, WF-13, and WF-14 as outlined in Figure #5 & #6. You will need to bend the LB s to obtain the correct angles. 24. Using nuts & bolts and LB s, take the connected WF-08 and WF-09 piece and attach it to WF-12, WF-13, and WF-14. You will need to bend WF-08 and WF-09 at the seam, as well as adjusting WF-12, WF- 13, and WF-14 to fit everything properly. See figure #5 & #6 6

Figure #6 (inside view) 25. Locate RIB-01U, and attach both ends to WF-01 with nuts & bolts and LB s. Ensure the middle seam is lined up with the middle of WF-04. See figure #7 26.

8 Figure #6 (inside view) 25. Locate RIB-01U, and attach both ends to WF-01 with nuts & bolts and LB s. Ensure the middle seam is lined up with the middle of WF-04. See figure #7 26. Attach one end of a FAS to WF-12 with wood screws and the other end to WS-01 with an LB and nuts & bolts. Prior to drilling and bolting the LB to WS-01, measure the distance between WF-10 and the floor to ensure that both eyebrows are at the same height. See figure #7 & # Attach both ends of RIB-02U to the lower corner of WF-12 with nuts & bolts and LB s. Ensure the middle seam is lined up with the middle of WF-04. See figure #7 28. Continue by attaching both ends of RIB-04U to the upper corner of WF-12 with nuts & bolts and LB s. Ensure the middle seam is lined up with the middle of WF-04. See figure #7 7

9 Figure #7 (front on) Figure #8 (side view) 29. Attach RIB-05U on top of WF-08 with LB s and nuts & bolts. See figure # Attach RIB-07U on top of WF-09 with LB s and nuts & bolts. See figure #9. 8

Attach RIB-09U to the ends of WF-03 and WF-07 with nuts & bolts and LB s. 33.

10 Figure #9 (inside view) 31. Continue by attaching RIB-08U to the mid-point of WF-03 with nuts & bolts and LB s. 32. Attach RIB-09U to the ends of WF-03 and WF-07 with nuts & bolts and LB s. 33. To date, I haven t installed the back wall and door onto my shell. Therefore, please follow Diagram #1 to complete your construction. It looks really simple. 9

11 34. To strengthen the shell further, I strongly advise you to install numerous pieces of aluminium or wood strapping across each RIB section. 35. That s it, your done! 10

Straight Stringer Installation Instructions

Straight Stringer Installation Instructions Floor-to-Wall Installation F L I G H T P L A N Unpack: What s included? Your Stringer Tread Screws (8) per tread (1) Torque Wrench (1) Socket (for the brackets