Rigging the wing is as much an art as a science. The objective is to get all the compression struts parallel to the keel tube on both wings and at the same time ensure that the front and rear spar tubes are straight and not bowed in any direction. All of the Landing wires will be rigged with one end already swaged and the other end clamped in place with the swage slugs ready to be swaged. Having the landing wires clamped on the end that connects to the spar tubes allows you to adjust the wing once its mounted in place on the power pod. Only when all rigging is in place and you have done your checks for wing wash, is it safe to do the final swaging on the landing & flying wires.
The rigging process is the #1 most important part of building your kasperwing. Mistakes made here will directly effect the flight characteristics and performance of your kasperwing. You should not attempt to fly the kasperwing unless you are 100% sure the wing does not have any wash-in and no more the 1º of wash out. It is best to rig the wing indoors as even on a calm day a light breeze can cause the clamps to slip and will make the rigging process a nightmare. I am currently attempting to rig my wing by myself and I can tell you that the task is way to difficult to attempt yourself. You will need at least one helper to properly rig the wing. If a helper is not available or not an option then you will need to rig up some type of adjustable struts to aid in wing support and alignment. What I did (and recommend) is to use a spare piece of 6061-t6 tube and a pair of visegrips to support the spar you are rigging. The vise-grips can be moved up and down on the tube to accommodate different spar heights and conditions. This worked very well for me :) You need a tube of at least 8ft to do this correctly.
Step 1- You will need an area free of obstruction that is at least 40' x 20' but I recommend a space indoors that is 100' x 50' if available. The only space available to me was my back yard so I had to lay out a tarp that was 20' x 40' to work on. If you are working on a grass surface then the tarp is Required! Lay the tarp out and secure it in place with some stakes. Lay out all the wing spars and keel tube assembly and bolt them together.
Step 2- From a roll of 3/32 7x7 coated aircraft cable cut the following lengths of cable and swag one end in place as follows.
2 pieces @ 112" long
2 pieces @ 178" long
2 pieces @ 105" long
The forth cable is not specified in the shop manual as to its length but you can make this cable up as you go.
The cable that is 105" in length is the front inboard landing wire and it is the #1 position on the kingpost (first toward the front).
The cable that is 112" long will be the trailing edge spar inboard cable and sits in position #3 in the kingpost.
The cable that is 178" in length is the outboard leading edge and is #2 in the kingpost. The unspecified length cable is outboard rear spar #4 in the kingpost.
Repeat process for both sides then clamp the cables in place with 2 swag slugs already in place but not swaged yet. The idea here is to get all 4 spar tubes straight (not bowed in any direction) and to alien the compression struts to the keel tube one wing at a time so everything is straight and in line with keel tube. to make the spars straight they must be rigged on an angle upward toward the outboard end (dihedral ).
Step-3 Once all the cables are in place, Swaged on the kingpost connection side and clapped on the spar connection end, you can disassemble everything and lay out the sail cloth bottom side up. Slip all the spar tubes and the keel post in place on the sail and bolt back together.
wing ready to be mounted on airframe
Note: if your working in a confined space now is the time to move the plane to its airport or hanger.
STEP 4- Once the wing is mounted on the frame you can start the process of sighting down the wing spars and adjusting the landing wire clamps to make the spars straight You will need a ladder to reach the rear spar claps and the vise grips and tube to adjust the height of the spar tube while you clamp it in place.
Compression struts in rough alignment
The Left Wing is in its final clamped position. Once the right wing and lower fly wires are in place everything can be crimped in place.
Complete and ready to fly