SonexBuilders.net

So there’s this bracket you need to make in the stabilizer skeleton to hold the aft root rib to the forward spar. You have to open up a 2”x2” angle from 90 degrees to 95.1 degrees. Aside from not knowing how to measure that 0.1 degree, the bending was made easier with a claw hammer and my big Chinese vise:



Careful measurement showed that I got it to 95.5 – but a quick rap with the hammer drove it back down to where it needed to be:



A quick pass on the belt sander took the little bit of curve out of the outside flats, and it matched the drawing – as close as I could tell.

Making all these brackets and clips is kind of fun!

Paul

Looks like this technique may give you more control than the one in the Sonex Hints video using a wrench. Let us know how it goes on a longer part like the fuselage angle where the wings attach. I had such a rough time getting a consistent angle on those fuselage angles that I just ended up buying it from Sonex pre-bent.

When faced with a dimension or angle that is beyond my ability to measure, I use the force. It was good enough for Luke to blow up the Death Star.

Bryan,

I know that is not true! Well maybe you use the force but I'm certain you can measure to the tenth of a degree! You were showing us your engineering skills on the hockey sticks on your Waiex tail!

Interesting technique with the claw hammer!

Looks good. Might I suggest you slip a piece of scrap sheet aluminum between the jaw and your angle, helps keep the angle from getting scuffed up.

Hi Paul,

I am also building a Xenos that I started 12/13. Tail pieces and main wing spars done and working on the rear spars now. I used my hydraulic press mostly on opening up the angles. I have a 1" dia. rod the angle rests on and press down on the angle corner with wood under the ram. I pump a little then measure & repeat until I get there. I'll find out later if my lack of the .1 deg accuracy makes me fall out of the sky.

Rick Caldwell
Melbourne, FL
RV-6 1999
One Design 2002
Xenos #0057 11 mos. into it.

To bend the fuselage angles for the spar box area I bought some vice jaw protectors at Home Depot. They had a horizontal notch formed in them to hold a pipe. I also purchased a foot long by 1 1/2 in. dia black pipe. I put the closed edge of the angle in one side of the jaws and the black pipe then fit inside the angle and the small V groove in the other jaw. Closed the vice until I got the angle I needed. I did need to slide the angle piece thru the vice and crank down again to get the full length of the angle spread as needed. This did seem to work pretty good. I am sure I got within a tenth or two of a degree of the required angle. HA HA
Don
Waiex 132