SonexBuilders.net

So I've been working on my Waiex (-B, but I hear they are the same at this point) tailkit for a bit now, and I've gotten to the point on the ruddervators that I'm going to trim the skins to size.

However, upon inspecting the skins, I've found that I have no pre-punched / cut / laser'd holes to start alignment from.

Isn't the kit made up of laser-cut skins with pilot holes?
Is this the only area in this section without? Did I get a dud? Am I misunderstanding?

https://youtu.be/012eSYzZpBo?t=78
I certainly don't have any holes to start from like the gentleman there.

Thanks all!

Which skins were you looking at?

I'm a Sonex guy, but the VS/elevator skins were predrilled and the rudder/elevators were not. These control surfaces (along with the ailerons and flaps on the wings) were among the only parts in the entire plane that seem to not have at least 1 of the parts predrilled.

Mike is right. On the control surfaces there are no predrilled holes. On my build thread I showed a tool to help mark out the hole locations.

Page 53 of my thread is where the detail is.
viewtopic.php?f=39&t=578&start=520
This is for the ailerons but it is pretty much the same for all control surfaces.

That makes me feel better at least.

The scrap-tool looks like a great idea. I'll have to make sure I cut a piece that can be used in a similar fashion while trimming the skins.

I'll also have to pull the stabilator skins out of the box and really look them over. It'll be comforting to know that I have a place to start from on those.

Bryan, is there a preferred way to fold the skin overlap on the ruddervator skins? Does the edge go over creating a hard edge or fold under? Does that make sense?

It seems like "under" would be more aerodynamic and aesthetically pleasing.

The short edge should definitely be on top else the metal won't lay flat on the leading edge of the rib. Plus neither you or the airstream will see it later. General construction order:
1) pilot drill the hinge. My technique is here:
viewtopic.php?f=34&t=1877
Others use the ruler trick.
2) transfer hinge holes into the short edge only. Put the hinge aside.
3) Drill the front of the ribs to the skin. Make sure they are pushed down tight against the skin on your nice flat table. Skip the hole where the hinge goes.
4) drill the rest of the ribs to the skins.
5) take clecoes out of the top skin (ruddervators and ailerons, bottom skin for flaps) so you can lay it on the nice flat table. Using my tape trick transfer the hinge holes to the other half of the front skin.
6) cleco the hinge on, put the clecoes back in the top skin, and updrill everything.

Though there are no CNC holes the control surfaces were fun and easy to do.

Awesome, thanks for taking the time to write that all out.
I'll be trimming skins next and then hopefully layout begins!