Cotton Waiex 191 - N191YX

[Gripdana]

Whats that stuff falling off the tent? We haven't had that for about 4 maybe 5 years. I had to let my grass go last month. I am now removing 1500 sq ft by hand. I wish you could send some of that water here! Your project is looking good!

[Bryan Cotton]

Dana,
We have plenty of water to send! The corn is going wild out here.
Adam riveting aileron drive horn ribs:


Riveted drive ribs and a start on the counterbalance. One tip, do not try and drill lead with a #40 bit. It just sticks in there. After figuring this out I went right to a #21 and it was good.

[Bryan Cotton]

Here is my method for building the aileron counterbalances. There are two little angles that form a channel and rivet between the counterbalance arms that have matched holes to the arms. The trick is that the ribs do not have the holes yet, but need to line up with the angles. Can't cleco them on. I used some 3/32" pop rivets as a temporary fastener. In the picture below, the arm on the right has just had two pops set. The left arm has one rivet tail that has been sanded down near flush. It's other pop was first sanded, then I used a #30 drill on it until it was just flush.


These rivets are strong enough to hold the parts in alignment. I clecoed the arm together without the ribs, blocked it up, and witnessed the 3 3/8" height to the top of the arm:


I then added the ribs, and used a straight edge to align the front flange of the ribs to the angles:


After I had a couple gnu-vise clamps on I flipped it over and added another on the other side. Dissassemble, transfer all the holes except for the pop riveted ones, dissasemble more to deburr, remove pop rivets, reassemble, and get the last two holes where the pops were.


Need to drill the lead block holes to final size, edge finish, then it is time for the chief riveter.

[Bryan Cotton]

Counterweights done. Need to mark out hole locations on the skins next.

[Bryan Cotton]

Did I ever mention that I'm lazy? After marking out rivet locations for one rib on the top, bottom and front I made a template from scrap:


It hooks over the edge to locate the holes each time.


To drill the pilot holes I made a "rib" out of a 2X4. Supports the skins while drilling.


Looks like I will be at Oshkosh Thursday and Friday.

[Bryan Cotton]

I started looking at panel layout. Boy there is not much room! Still have the ICS, turn needle, and switches to go. Just a few switches - master, mags, chemtrails, nav lights, landing lights, wig wag.

[Gripdana]

Hi Bryan,
It looks to me some of your instruments are too low on the panel. If you have the panel tilted back per the plans you may have interference with the lower cross tie. The space is small and I had to move thing up on mine to clear.

[Bryan Cotton]

Thanks for the comments Dana!
We got back from Oshkosh Friday night. Arrived Thursday morning. It got Adam fired up. Here he is drilling our ailerons together.

[Bryan Cotton]

John Monnett says I should spend less time posting and more time building. He is probably right! I was pleased he reads this stuff and remembered me when I stopped by the booth. Hopefully this helps somebody who spends more time building and less posting.
Right aileron tip cap:

The fit is not spectacular, but good enough. Moving on!

[Bryan Cotton]

Here is my technique for transferring hinge pilot holes to the long unsupported section of the part. I use good duct tape with a little fold in the middle so I can grab it with pliers.


My ailerons are ready to polish and rivet. Here are the skins on the shelf. Got the flaps down and I have started them.