Cotton Waiex 191 - N191YX

[Rynoth]

If you use a Hartwell latch on the fuel filler door you will be happy in the long run. It sure makes it a lot more convenient to visually check your fuel level and the security of your fuel cap as well as when fueling.

I assume Bryan was insalling one of these southcos that are just as easy to operate and also dont require tools.

[daleandee]

I assume Bryan was installing one of these southcos that are just as easy to operate and also dont require tools.

https://www.google.com/search?q=southco ... nu3hqMf_KM:

I used a Southco that does require a tool ... same tool I use for opening my cowling doors on pre-flight & checking my Mogas for Ethanol. It is also used to to sample fuel from my (still installed) gascolater. Looks like this:




Dale Williams
N319WF @ 6J2
Myunn - "daughter of Cleanex"
120 HP - 3.0 Corvair
Tail Wheel - Center Stick
Signature Finish 2200 Paint Job
171.9 hours / Status - Flying
Member # 109 - Florida Sonex Association

[Bryan Cotton]

I found a Hartwell on eBay for $20 shipped. But, it looks heavy and is expensive compared to a Southco. I am leaning towards the wingnut style for the fuel door.

[achesos]

Bryan,

More often than not, I apply the smart-not-hard approach...
Slightly outside the box here, but how about a new door instead of moving the hole to be under the existing one?

Cosmetically, maybe there would then be a bit a asymmetry that might drive you crazy with a new door, and/or only a handful of folks besides AirVenture judges will notice. Probably an internal tolerance level thing - judging by how much time you have invested in polishing, I'm betting you'll move the hole.

Not quite 2 cents there - good luck.

[Bryan Cotton]

Sean,
Adam and I were discussing a new door. One of the possibilities.

[Bryan Cotton]

Adam made a new door. People aren't symmetrical either! Still looks ok.


Here is our front Southco setup:


A shot from inside. We used metal rather than fiberglass.


Didn't get to work on the airplane last week. I was in Austin, Texas at National Instruments for LabVIEW training. While I was gone the golf cart blew up slightly.

[Sonex1243]

Looking good Bryan. Hope your "cruising" the neighborhood series isn't affected too terribly!

[Bryan Cotton]

Here is our new portable jack. It has wheels and disassembles for easy storage in the back of the Waiex. Not sure what all the jacking fuss was about.


In the 3 point attitude the plate was 8 degrees nose down and the airplane was 9.5 degrees nose up. So, our hole pattern needed to rotate 17.5 degrees. We used this simple setup.


Afterwards we will cut out the red line and have a new template.

[Bryan Cotton]

We found some primed 7075 in the scrap bin. Adam has drilled the holes and is marking the cut lines.


Here is a view of them mounted. They look much better.

[Bryan Cotton]

To drill the pilot holes in the wheel pants, we made this tool. It is a box with two holes across from each other, 11" back, and 2.5" high per the plans. A 2 by 6 is the perfect width.


Here is the tool in action. Any local Sonex builders, you want to borrow this.


We went a little oversize on the holesaw - 2" rather than the 1.75" called for in the plans. Lets us miss the caliper bolts with no drama.


Here Adam is cutting out the slot.


I cut the first axle. Spark city!


Adam cut the second one.
https://youtu.be/k2xBTCHfV7M

One wheelpant:


And two: