Wing Hardpoints

This blog covers manufacture and installation of the external wing hardpoints.

Overview
One of the things that change the Tucano into a military replica was the factory's addition of under wing tanks and it was decided this Tucano was to have a set. These tanks can be used as additional luggage or fuel tanks offering 25 liters per side. 

As the factory is yet to finalize their design so to some degree I am on my own devices to proceed.

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Manufacture
The factory has supplied drawings to manufacture the hard points from 0.160'' aluminium to mount underwing storage and these are custom profiles to suit this aircraft. Once completed DXF files were sent out for laser cutting, when received all parts were de-burred and alodined.

Brackets and tanks
Note these tanks are just drawings as
the fuel tanks are a way off

Installation
The rear bracket was installed by locating it about the center of the lighting hole in the rib. Once located a length of aluminium was drilled at the required mounting distances and bolted to both hard points. The front point was then swung into position on the rib and match drilled.

Front mount with aluminium spacer

Rear mount secured for drilling

With all holes drilled the parts were removed - deburred and then fixed using 3.2 mm OD multi grip rivets.

The next task was to slot the skins to accept the hard points, cardboard templates were created using the mounting holes on the rib locating the lug in reference to the rivet holes as locating points. The profiles were then marked onto the skin using a cardboard template referenced to the matching rivet holes in the skin allowing it to be marked onto the outside of the skin.

The slot was marked and filed to clear the mounting point with the gap to be sealed with a silicone fillet at final assembly.

Cardboard jig and skin slotting

Finished installation

Port Wing Installation
Installing the points on the opposite wing followed the same procedure BUT a jig was used to set the location of the rear hardpoint to allow any tanks to fit either wing.

The jig was a length of 25 x 25 x 1.5 aluminium angle from the hardware store that was match drilled to the starboard installation, then the nose attachment was installed with reference to the starboard side.

Next, the jig was bolted to the nose attachment as was the rear attachment and then this assembly was swung into position after checking the starboard side the rear attachment was riveted into position.


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