Cotton Waiex 191 - N191YX

[Sonex1243]

Great idea on the wing tip drilling tool Bryan, you always come up with something nifty. Do you recall any "tricks" for the 1/16" bevel on the fuselage splice plates? I am toying with an idea of a chamfer router bit in the drill press and swiping the flat parts across it and drill table set at a certain height to avoid a lot of filing / fitting.

[Bryan Cotton]

Ken,
I think I just used the vixen file followed up by the angle sander with scotch brite. I think that this is one of those jobs where the hard way is the easiest.

[Bryan Cotton]

Here is my setup for pilot drilling the control sticks. It is important to use a spotting drill due to the angle of the weldment where the bit first makes contact.

[Bryan Cotton]

I have a bunch of 5/8" flat reamers. I was able to run them through by hand without a handle.


I could not get the other part of the stick through. I did have another 5/8" steel tube that was a little smaller. Another argument for polish over paint- I put some F9 on the bushing and tube and polished it up to a larger hole size.


After polishing with the tube, I repeated the process with the control stick part. Then I cleaned out the F9 and made this jig to align my stick halves.


The plans specify some small clearance to limit fore-aft movement. I am going to make it tight and sand as required.

Adam has been busy so I am doing other things besides rigging the wings.

[Bryan Cotton]

Here is the right stick jigged up on the drill press.


It came out good. I can see the bolt head and nut will not be sitting flat due to the geometry of the weldment.


Did you A) make a nifty shim, B) fill the void with epoxy, C) squash the weldment a bit, or D) don't tighten overmuch as this is a shear bolt anyway.

[Sonex1517]

I went with D, but I used taper pins


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[sonex892.]

I went with D, but I used taper pins


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Ditto with Robbie. Now using a taper pin. Replaced the bolt 3 years ago.

Steve
Sonex 892

[Bryan Cotton]

Adam and I had a few details to finish up, like riveting the left hand aft root rib:


Then it was time!


Our sawhorses were too high so we had to cut a couple wooden ones down 6".


We didn't get the wings pinned, but hey it is a start!


Very cool. Reminds me of rigging a glider.

[wlarson861]

Drilling the attach holes is a mentally draining exercise but is really easy. Make sure everything is lined up and go for it!! Over thinking and second guessing are the enemy. Getting the wings on permanently is a big milestone in the build and one you will relish as you finish everything else. Ready to see your report.

[Bryan Cotton]

Wings are pinned together and to the rear carrythrough.


Level on one side:


And on the other side:


We used windshield washer fluid. See some of you Saturday at Clow!