Cotton Waiex 191 - N191YX

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Re: Cotton Waiex 191 - N191YX

Postby Bryan Cotton » Sun Oct 15, 2017 9:00 pm

Thanks Ryan! We may end up doing that as well.

I used a stick with an angle cut in the end to back up the lexan, while Adam drilled.
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One side clecoed in:
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It seems like it would be easier to drill the windshield bow first, then transfer the holes.
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 25, 2017 10:54 pm

We made a little tool to mark our holes in the bow. It centers the bit, and sets up the entry to be perpendicular to the windshield.
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Next we went to the drill press and V block to run the holes through.
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Finally we transferred the holes to the lexan.
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: 4957
Joined: Mon Jul 01, 2013 9:54 pm
Location: C77

Re: Cotton Waiex 191 - N191YX

Postby kevinh » Wed Oct 25, 2017 11:26 pm

smart! I'm going to copy that one! ;-)
Taildragger Waiex in progress, tail done, wings done, about to mate wings to fuse,
then cowl, canopy, paint (photos): flush rivets, turbo aerovee, acro ailerons
(I built my RV7A and happily flew it for about 500 hrs)
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Re: Cotton Waiex 191 - N191YX

Postby WaiexN143NM » Wed Oct 25, 2017 11:50 pm

Hi bryan,
Good to see u back at it. Hope to get ours up from tucson osh -18. Would be a pleasure to park next to you and adams creation! Cheers keep at it!! Maybe kevin will make it too!!

Waiex N143NM
Michael
WaiexN143NM
 
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Re: Cotton Waiex 191 - N191YX

Postby Bryan Cotton » Thu Oct 26, 2017 7:16 am

Thanks guys! Hope we have a strong turnout for the Sonex brotherhood in 2018. Not sure if we have any sisters in the ranks, time will tell. One other detail in that last picture: see the Gnu vises? It is clamping an angle to the rear wing mount angle. There is a small piece of angle (hovercraft motor bracket, actually) on top of it. It is holding the bow from sliding down. We tapped it up so the bow was tight then locked it in place on either side.
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: 4957
Joined: Mon Jul 01, 2013 9:54 pm
Location: C77

Re: Cotton Waiex 191 - N191YX

Postby Darick » Thu Oct 26, 2017 8:36 am

Small block of wood to get the entry/angle correct!! Great idea...I never felt happy about drilling holes into a round bar.
Darick Gundy
Sonex #1646
N417DG
Taildragger, Aerovee, center stick, Prince P-Tip Prop
MGL E1, F2, V6 radio, Sandia Xponder, Reserve lift indicator (AOA), iFly 520
First flight! 10/21/2017
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Re: Cotton Waiex 191 - N191YX

Postby Bryan Cotton » Mon Oct 30, 2017 1:05 pm

Here Adam is drilling his side for the bow mount​. We have trimmed the lexan. I wish Sonex had not routered that groove for the bow.
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: 4957
Joined: Mon Jul 01, 2013 9:54 pm
Location: C77

Re: Cotton Waiex 191 - N191YX

Postby Bryan Cotton » Tue Oct 31, 2017 9:31 am

I did not have a countersink for an 11/64" hole. Instead we used our deburring tools. It worked good. We put a #8 dimple in scrap to check the countersink depth.
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: 4957
Joined: Mon Jul 01, 2013 9:54 pm
Location: C77

Re: Cotton Waiex 191 - N191YX

Postby Bryan Cotton » Sat Nov 11, 2017 8:44 pm

Here I am using my fan spacer to pilot the longeron hinge.
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We elected to make those plywood pieces as we were ready for that step. I marked the turtedeck curve after we pinned the rough cut wood to the tooling holes, then used scrap lexan to mark the cut line.
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Soon we will make the first cut.
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: 4957
Joined: Mon Jul 01, 2013 9:54 pm
Location: C77

Re: Cotton Waiex 191 - N191YX

Postby Bryan Cotton » Mon Nov 13, 2017 11:24 pm

We have made our first few cuts. So far, so good. We drilled a hole to pick up the center bow screw as the masking tape could not hold the canopy down.
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We also used a ratchet strap for the same reason.
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Here I am sanding the edges.
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Time to put it away for the night.
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: 4957
Joined: Mon Jul 01, 2013 9:54 pm
Location: C77

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