Cotton Waiex 191 - N191YX

[Sonex1243]

Looking good Bryan. Did you up size the wing blocks all the way?

[Bryan Cotton]

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]

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.


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.


Obviously I pulled the 3/16" bit out after I clamped it down.

[Bryan Cotton]

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.


My last pass was with a .3725 reamer. Had to gently tap the bolt in. Success! Halfway done, left side is still 3/16".

[onex28]

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

[Bryan Cotton]

Thanks David!

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


Then the other:


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.

[onex28]

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

David

[Bryan Cotton]

Root rib angles:


I am waiting for new, shorter flush bolts to come for the spar mount angles. The specified lengths were very long.

[Bryan Cotton]

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]

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.