Cotton Waiex 191 - N191YX

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Re: Cotton Waiex 191 - N191YX

Postby Sonex1243 » Sun Oct 25, 2015 9:51 pm

Looking good Bryan. Did you up size the wing blocks all the way?
Ken S
SONEX #1243 N424SX (reserved)
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Re: Cotton Waiex 191 - N191YX

Postby Bryan Cotton » Sun Oct 25, 2015 10:12 pm

Not yet Ken but I will. I drilled the blocks by themselves in a drill press vice. Adam did a couple of them the same way. I figure before I drill up I need to figure how to clamp the whole spar on the drill press table. Thanks also Michael, Ken and John for the encouragement.
Bryan Cotton
Poplar Grove, IL C77
Waiex 191 N191YX
Taildragger, Aerovee, acro ailerons
dual sticks with sport trainer controls
Prebuilt spars and machined angle kit
Year 2 flying and approaching 200 hours December 23
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Re: Cotton Waiex 191 - N191YX

Postby Bryan Cotton » Wed Oct 28, 2015 10:39 pm

I drilled the three 1/4" holes in the spar. I used an egg cup drill bushing holder to get to 3/16" but did not have a 1/4" bushing. I drilled three through holes in a bar to 3/16" diameter. Then I drilled most of the way down with a 1/4" bit.
Image

Next I located the block with a 3/16" bit (which is why I didn't go all the way with the 1/4"), clamped in place, and drilled. The block guides the drill.
Image

Obviously I pulled the 3/16" bit out after I clamped it down.
Bryan Cotton
Poplar Grove, IL C77
Waiex 191 N191YX
Taildragger, Aerovee, acro ailerons
dual sticks with sport trainer controls
Prebuilt spars and machined angle kit
Year 2 flying and approaching 200 hours December 23
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Bryan Cotton
 
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Re: Cotton Waiex 191 - N191YX

Postby Bryan Cotton » Thu Oct 29, 2015 11:09 pm

Got my spars rigged up in my drill press. Used my truck canoe rack, plus a step stool, wood blocks, and a bottle jack since I had to offset it.
Image

My last pass was with a .3725 reamer. Had to gently tap the bolt in. Success! Halfway done, left side is still 3/16".
Image
Bryan Cotton
Poplar Grove, IL C77
Waiex 191 N191YX
Taildragger, Aerovee, acro ailerons
dual sticks with sport trainer controls
Prebuilt spars and machined angle kit
Year 2 flying and approaching 200 hours December 23
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Bryan Cotton
 
Posts: 5175
Joined: Mon Jul 01, 2013 9:54 pm
Location: C77

Re: Cotton Waiex 191 - N191YX

Postby onex28 » Fri Oct 30, 2015 8:35 am

Way to go Bryan. That's why I enjoy the building process, you get to devise all sorts of ways to jig up a part to perform an operation.

David
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Re: Cotton Waiex 191 - N191YX

Postby Bryan Cotton » Sat Oct 31, 2015 2:44 pm

Thanks David!

To check for trueness, I did 3 things. Check for square on one axis:
Image

Then the other:
Image

Note I used a reject wing block to help. Remember what I said about allowing for saw kerf? The third check is the 3/16" bit I used to drill the blocks should go in and out without binding.

Here is a super-interesting video of me drilling up the blocks on the left side:
http://www.youtube.com/watch?v=a5nJ0gXonHk

Maybe not that interesting. But I will point out the box holding the camera has my new Gaugepod wingtip light mounts. I haven't opened it yet.

I can push both bolts about halfway in by hand with light oil on them. Then I have to tap them in with the little plastic hammer. I am very pleased.
Bryan Cotton
Poplar Grove, IL C77
Waiex 191 N191YX
Taildragger, Aerovee, acro ailerons
dual sticks with sport trainer controls
Prebuilt spars and machined angle kit
Year 2 flying and approaching 200 hours December 23
User avatar
Bryan Cotton
 
Posts: 5175
Joined: Mon Jul 01, 2013 9:54 pm
Location: C77

Re: Cotton Waiex 191 - N191YX

Postby onex28 » Sat Oct 31, 2015 9:29 pm

Good video Bryan. Others will learn by it. You will like the Gaugepods, they are well made. I have them on my Onex.

David
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Re: Cotton Waiex 191 - N191YX

Postby Bryan Cotton » Wed Nov 04, 2015 12:25 am

Root rib angles:
Image

I am waiting for new, shorter flush bolts to come for the spar mount angles. The specified lengths were very long.
Bryan Cotton
Poplar Grove, IL C77
Waiex 191 N191YX
Taildragger, Aerovee, acro ailerons
dual sticks with sport trainer controls
Prebuilt spars and machined angle kit
Year 2 flying and approaching 200 hours December 23
User avatar
Bryan Cotton
 
Posts: 5175
Joined: Mon Jul 01, 2013 9:54 pm
Location: C77

Re: Cotton Waiex 191 - N191YX

Postby Bryan Cotton » Tue Nov 10, 2015 10:26 pm

Adam set his first 11 real AN470AD5 rivets today. We practiced on scrap first.
http://youtu.be/tNlD0cddsKM

Some of you may wonder why 11- he smiled one up real good and we had to drill it out. Perfect. You can't really learn to rivet unless you make mistakes. Probably true for anything worth learning. I tried to teach that lesson on the scrap but a real experience is better.

The 10 keepers are awesome.
Bryan Cotton
Poplar Grove, IL C77
Waiex 191 N191YX
Taildragger, Aerovee, acro ailerons
dual sticks with sport trainer controls
Prebuilt spars and machined angle kit
Year 2 flying and approaching 200 hours December 23
User avatar
Bryan Cotton
 
Posts: 5175
Joined: Mon Jul 01, 2013 9:54 pm
Location: C77

Re: Cotton Waiex 191 - N191YX

Postby Bryan Cotton » Wed Nov 11, 2015 12:21 am

Adam's riveted stiffener and some spacers. I was trying to transfer holes from the web to the spacers but it was a bear to clamp. Ruined one spacer. Then I thought to make a mild steel tool, which you can see in the picture. I will try it out another day.
Image
Bryan Cotton
Poplar Grove, IL C77
Waiex 191 N191YX
Taildragger, Aerovee, acro ailerons
dual sticks with sport trainer controls
Prebuilt spars and machined angle kit
Year 2 flying and approaching 200 hours December 23
User avatar
Bryan Cotton
 
Posts: 5175
Joined: Mon Jul 01, 2013 9:54 pm
Location: C77

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