Cotton Waiex 191 - N191YX

[Bryan Cotton]

Modified the forward root ribs. Should have done this before!
Hack job:


Cleaned up:


Here is a template I made to mount my fresh aero lights. The template was scaled a bit small so I did not use it. I used the dimension from the front of the rib. Also I noticed the dimension for hole spacing on the bracket did not match my parts. My template uses the tooling holes for alignment.


Once I get my brackets mounted it is deburr city. Man there are a lot of holes.

[Darick]

Bryan said, "I needed shims under the aileron bellcrank structure. I will mark the shims and trim them. I may flush rivet the shims to the angles so they don't get lost."

Bryan, I had to add a shim under my bellcrank structure too. That's a good idea to flush rivet them. I didn't and it was a chore to keep them in place while drilling, deburring, etc.

[dtwolcott]

That sure looks a lot better than mine. It was a lot harder to blend the new flange around the newly created hole with the existing holes after the wing was completed.
Don

[Bryan Cotton]

Darick,
A hummelbird builder I know super glues his shims in place. Clever, but an AN426AD3 is more my style. Thanks Don, though I must confess the job is easy when the rib is not installed.

Let there be light! This is the other part of the Fresh Aero kit.

Can anybody give me a suggested angle for aiming the light down?

[Bryan Cotton]

Deburring has started in earnest:

I got my left side Whelen Orion 600 nav/strobe today. I am splitting up the purchase to ease the sticker shock. Hooked it up to the 12V drill battery to check it out - Awesome!

[samiam]

Great to have an extra set of hands working, that's a lot of deburring!

[Bryan Cotton]

And polishing!

[Rynoth]

And polishing!

If I can give 1 piece of advice Bryan, it would be to go full C grade (or S if you're feeling lucky) on the bottom skins before riveting. Unless you want to polish them after assembly on a rack or bench. Might save you having to polish from under the plane for a few years (or forever.)

[Bryan Cotton]

Ryan,
That is a good thought, thanks. I am torn between doing as you say and just never looking under there!

[DCASonex]

Ryan,
That is a good thought, thanks. I am torn between doing as you say and just never looking under there!

Best to do both. Polishing any part is much easier while a flat sheet on a table. Then don't look under there, it gets messy. Mine has polished underside of fuselage and only wash under there a couple of times a year, just finished fourth year (265 tach hours) , and have not re-polished underside, still looks pretty good. Coating oil from exhaust of old Jabiru engine seemed to provide some protection. That "benefit" is now missing with the new CAE engine which uses very little oil.

David A. Sonex TD, lazy man's polish on top sides of wing and tail, plus fuselage, all else, including all control surfaces, painted.