Summary of Contents for Freight Wing Aeroflex
- Page 1 Aeroflex Belly Fairing Pre-Assembly Manual Freight Wing Incorporated 4015 49 Ave SW Seattle, WA 98116 info@Freightwing.com TOLL FREE INSTALLATION HELP LINE: 866-464-9464 Copyright © 2010, Freight Wing Inc. Rev 8/1/10...
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Page 2: What You Will Need
Introduction The following manual will guide you through the procedure for assembling the Aeroflex panels and rods. The procedure to takes approximately 1.5 man hours per unit once familiar with the process, and is necessary for bulk packaged units only. Note that the procedure for installing the assembled fairing on the trailer is outlined in a separate installation manual. -
Page 3: Important Notes
Assembly Instructions Important Notes: The pre-assembly involves bolting the hinges to the panels. The process is simple, however some organization is helpful. Each of the six panels in the fairing are different. The font, middle and rear panels all have a left and right side as illustrated below. This is so that the natural curve in the TPO plastic material faces inward toward the center of the trailer. - Page 4 It is also important to note that that middle and rear panels are slightly longer than the hinge so that they can overlap when mounted on the trailer. Therefore the hinge will not extend over the last slotted hole on the side of the panel with slotted holes along its edge as illustrated below on a middle panel.
- Page 5 Step 1: Barrier Tape the Hinges When mounting the faring on trailers with steel cross members (typically dry vans), place separation tape on the aluminum hinges to create a barrier that will separate the metals to prevent corrosion. This step is not necessary when mounting on trailers with aluminum cross members (typically reefers).
- Page 6 Step 2: Assemble the Long Hinge on the Panels 2a. Gather the ¼” carriage bolts, ¼” nylon insert lock nuts, and the ¼” plain nuts supplied. 2b. Place a panel on the table with the inside face of the panel upward. Important: The letters marking the panel (LM, RR, etc) will read correctly (not backwards) when the inside face of the panel is upward as illustrated below.
- Page 7 2d. With the hinge slightly open, place carriage bolts in the square fastener holes. Note- If the panel is a front or middle panel, do not place one bolt in the hole on the side of the hinge corresponding to round holes on the side of the panel as illustrated below and in the figures on p.
- Page 8 2f. Lift the panel slightly and place it onto the hinge so that the bolts go through the holes in the panel. Note that most of the panel holes are slotted but the ones in the middle are round. It therefore helps to start placing bolts in the middle at the round holes.
- Page 9 2h. Place the ¼” plain (non locking) hex nuts onto the top of the carriage bolts. 2i. Hand Tighten the ¼” plain hex nuts. It is important that the nuts are snug on the backing strip but not tight. This allows the panels to expand and contract with temperature variations. As a faster alternative to hand tightening, a cordless drill with a clutch and a very loose clutch setting can be used (with a 7/16 socket).
- Page 10 2j. Place a ¼” nylon insert lock nut onto the top of all the carriage bolts. 2k. This step is very important as it ensures that the expansion slots on the top of the panels function correctly. Take a 7/16” wrench and loosen the 1 nut a quarter to a half turn.
- Page 11 Step 3: Assemble the small hinges on the panels 3a. Gather the ¼” button head bolts, ¼” ID rubber bonded washers, and the ¼” lock nuts supplied. Insert the rubber bonded washers on the button head bolts next to the head with the rubber side facing away from the head (64 per unit).
- Page 12 3e. Place a ¼ lock nut on the ends of all the bolts. 3f. Tighten each lock nut while holding the bolt head with an allen key and fastening the nut with a 7/16 socket. This connection should be firm but do not over torque. 3g.
- Page 13 Step 4: Assemble the Support Rods 4a. Gather a bracing strut, 5” bolt, bolt sleeve, 3/8” nylon insert lock nut, a 3/8” plain nut, two 3/8” rubber bonded washers, two 3/8” flat washers 3/8”, and two clamp tabs as illustrated below. 4b.
- Page 14 4c. Place a rubber bonded washer on the bolt next to the plain nut with the metal side facing the nut. Then place a clamp tab on the bolt with the angle facing the thread. Then place the bolt sleeve on the bolt. Then place another clamp tab on the bolt with the angle facing the other clap tab such that they are opposing.
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