Cotton Waiex 191 - N191YX

[ScottM-Sonex1629]

Well good luck!

[Bryan Cotton]

Looks like I got about 19.8 degrees rather than 19.6. I am going to cleco it all together and see how it looks. If the .2 degrees is messing me up my friend Mr. rubber mallet has offered to help.

[Bryan Cotton]

Hockey stick clecoed in, skin clecoed down, stab clecoed on:


Darn! That .2 degrees is killing me.

[ScottM-Sonex1629]

Bryan has anyone ever mentioned you might have OCD?

Looks great to me!

[Bryan Cotton]

Scott,
Nobody has mentioned it. Actually I am just lazy, I don't want to have to flex parts prior to clamping/drilling/bolting. I did tweak it in to 19.6 degrees.

[Bryan Cotton]

Here is my setup for transferring the 3/16" root rib angle mount brackets to the new hockey stick. I started out with the bottom hole. Cut the threads off a long AN3. This bolt lines up my guide block, the angle, and the spar C channel. The hockey stick is clecoed to the front of the spar. With the bolt in I put two clamps on, withdrew the bolt, and snake drilled it. Then I took another threadless AN3 to line up all those holes and repositioned my guide block. Still have to get one more clamp on.

[Bryan Cotton]

No picture, but I have started riveting the hockey stick back in. That is good.

We are starting to assemble the spar tunnel. Clecoed it to a piece of wood so we can go wild with the drill press.

Look right so far?

[Bryan Cotton]

The new hockey stick is riveted in. Words cannot describe the joy.


Some oops rivets. Cherrymax CR3243-4-1. The body is .140" before upset.


I actually have the 8 nose rib rivets on the other side before I can claim victory. Right now though I am claiming tired.

[Bryan Cotton]

All riveted and the trial fit is good. That .2 degree tweak was totally worth it.

[Bryan Cotton]

Holes located in the new shim and lower angle, for the right hand stabilizer.


To do things right the first time is easy. To fix a screw up takes real skill. So far I am into this repair about 15.5 hours and 19 days.