Aeroflex Belly Fairing Pre-Assembly Manual

Freight Wing Incorporated

4015 49th 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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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.

If we may be of assistance during the pre-assembly or at any time, please give us a call:

TOLL FREE INSTALLATION HELP LINE: 866-464-9464

What You Will Need The following tools are needed to assemble the Freight Wing Aeroflex Fairing:

1. A 7/16” wrench with an open end

2. A 7/16” socket

3. A drill (preferably cordless with a clutch) to tighten nuts with

4. An allen (hex) key set

5. Anti seize lubricant (if needed for stainless hardware)

6. Barrier tape (2” wide clear packing tape) and a razor (if needed for steel I beams)

7. It is helpful to have a large table (approx 8’x4’) or elevated surface to work on

Parts List

Freight Wing Part Number Description

Qty per Complete Unit

76-50174-02 Fastener Kit 12B (pre-assembly fasteners) 1

76-50174-01 Fastener Kit 12C (install fasteners) 1

44-50028-00 Hinge, Long (top) 6

44-50029-00 Hinge, Short (bottom) 16

58-50132-00 Panel Right Rear (RR) 1

58-50133-00 Panel Left Rear (LR) 1

58-50134-00 Panel Right Middle (RM) 1

58-50135-00 Panel Left Middle (LM) 1

58-50136-00 Panel Right Front (RF) 1

58-50137-00 Panel Left Front (LF) 1

68-50134-00 Backing Strip (Aluminum) 12

68-50132-00 Support Rod 16

68-50131-00 Clamp Tab 32

68-50133-00 Clamp Sleeve 16

68-50135-00 Square Hinge Washer 24

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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.

The panels are marked in the middle of the top edge with L, LM or LR for left front, left middle and left rear or R, RM, RR for right front, right middle and right rear. The mark is routed all the way through the panels so that it is visible on both sides. The lettering will appear backwards when read from the side of the panel that faces out from the trailer (this side of the mark will be covered by the top hinge when installed so that it is not visible). The marks read correctly from the inside of the panels as illustrated below.

Inside of left front panel Inside of right rear panel

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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.

Also note that on the middle and front panels, it is not necessary to place one bolt in the hinge on the side above the round holes as illustrated above. This bolt is placed during installation on the trailer because the panels overlap.

If you are installing several units, it can help to identify the panels and organize them into six piles for each panel type before getting started.

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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). Any corrosion barrier tape will work for this step, and 2” wide clear packing tape (polypropylene) can also be used and is a perfect width (preferably heavy duty packing tape that is thicker than standard tape).

1a. Gather 6 long hinges and place them closed on the table with the plain side (no fastener holes) facing up.

1b. Place tape (2” wide clear packing tape) across each hinge so that the tape is flush with the side edge of the hinge that is not pinned. Use a razor to cut the tape flush with either end. When done with all 6 hinges place them aside. (It is useful to have a tape applicator if taping multiple units).

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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. If the letters read backwards (like a mirror image), the panel must be flipped over. The long top edge with holes should be oriented towards you on the table.

2c. Place a slightly opened hinge in front of the panel as illustrated below, with the pin facing the panel and the fastener holes facing up.

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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. 3-4. Bolts will go in all the holes on rear panels only.

2e. Quickly flip the hinge leaf with bolts inserted over onto the table as shown below so the bolt threads face upward.

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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.

Note- If the panel is a rear or middle panel, the panel will extend beyond the hinge on the side with two slotted holes that are close together as illustrated below.

2g. Take two backing strips and align their holes with the bolts. Place the strip over the bolts, and

push it flush against the panel. There will be a gap between strips in the middle of the panel.

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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

th socket). Because drills and clutches are different, check to

make sure it produces similar results to hand tightening before proceeding.

Note- It can help to pull the hinge off the side of the table so that you can seat the carriage bolts in the square holes with your other hand as the nuts are tightened. Check for unseated bolts as illustrated below before proceeding and correct if necessary.

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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

st nut a quarter to a half

turn. The amount of this turn can depend on how tightly the 1st nut was fastened. You should

feel the tension ease indicating the nut has become loose and is not clamped tightly on the panel. Now hold the 1

st nut firmly in place with the 7/16” wrench, and fully tighten the 2

nd lock

nut down on top of the 1st nut. This will create a secure “jam nut” connection without tightly

camping the panels together, so that the expansion slots work properly.

2l. Repeat the process for all six different panels in each unit.

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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).

3b. Take a panel and place it so that it stands up vertically with the hinge away from you so that the holes in the middle of the panel can be accessed from both sides. The panel can be leaned against a wall or the table for support.

3c. Insert the ¼” button head bolts (with the ¼” bonded washers) through the holes in the center of the panel (grouped by lines of 4 holes) from the outer side of the panel (the side mating with the long hinge).

3d .Place the flat side of the small hinges with ¼” holes over the ¼” bolts on the back of the panel with the larger 3/8” hole facing the top of the panel as illustrated below. Rear and middle panels will both have 3 small hinges attached, and front triangular panels will have 2.

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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

7/16th socket. This connection should be firm but do not over torque.

3g. Repeat the process for all six different panels in each unit.

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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. Put a 3/8” flat washer on the bolt next to the head, insert the bolt in either end of the rod, then place another flat washer on the bolt, and then the plain nut. HAND TIGHTEN the plain nut so that is it snug against the washer and rod but not fully tightened. It is important that there are no gaps between these components as illustrated below. It is also important that the connection is not fully tight so that the rod can rotate on the bolt. A 9/16 deep socket and drill or impact can be used to turn the nut down quickly, but the final placement of the nut should be done by hand to prevent over tightening.

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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. Then place another rubber bonded washer on the bolt with the rubber side facing the clamp tab. Finish by hand tightening a nylon insert lock nut. The completed assembly is illustrated below:

4d. Repeat the process for all 16 rods in each unit.

The pre assembly is now complete and the fairing is ready for installation on the trailer (see trailer installation manual).

If you have any other problems, questions or comments regarding the installation procedure, please call our toll free installation help line:

TOLL FREE INSTALLATION HELP LINE: 866-464-9464