SonexBuilders.net

I must be the only one having problems with this as I can't find any other posts.
Is the tip supposed to be sandwiched between the rear spar and the skin (like the horizontal stab tips) or should you just cut a small piece out of the tip to clear the rear spar structure?



Also, the angle at the end of the main spar is already pilot drilled, for the tip attachment. It looks like I'll have to remove the bottom skin to get those holes transferred to the wing tip, by reaching through a lightening hole in the last rib. Since my x-ray vision failed some years ago I "see" no other way to do this. Am I overlooking something extremely simple or is this how Alzheimer's start?

Short version: You can cut the tabs off the aft portion to clear the rear spar, and you don't even need to drill/rivet the wing spar tip attach angle to the fiberglass, per this document from Sonex (that I wish I'd found before doing my own wingtips.)

http://www.sonexaircraft.com/documents/ ... nstall.pdf

Personally, I didn't receive this guidance and therefore cut small slots to clear the rear spar, and did undertake the painstaking task of transferring the holes on the tip attach angles to the fiberglass. I even dimpled the leading edge per the plans, but this instruction sheet says that's not necessary either.

Pics of my installation halfway down this blog post:

http://www.rynoth.com/wordpress/waiex/2 ... -skinning/

Thanks Ryan. Sometimes I remember to check the Sonex site for additional info, but obviously in this case I forgot. Yes, trimming to the additional instructions from Sonex will make this a lot easier.

There is some cutting to do. Here is a link to the Sonex instruction sheet for the wing tips.
http://www.sonexaircraft.com/documents/ ... nstall.pdf

My wingtips fit poorly, at least on the left side. I did read the instruction sheet. I was trying to line up the bottom edge with the wingtip, but now the skin overhangs the tip on the top. Seems like on the bottom the wingtip will have to stick out of the wing a bit. Unfortunately I have hacked it up enough that I either have to glass it up or get a new tip. Any thoughts on the tips?

I had to add and fill the glass to ge it to fit. One side was better than the other. I don't remember which side fit good

I had to do the same as Dana to get them to fit. I'm pretty sure the left side was the worst fit.

Bryan Cotton wrote:My wingtips fit poorly, at least on the left side. I did read the instruction sheet. I was trying to line up the bottom edge with the wingtip, but now the skin overhangs the tip on the top. Seems like on the bottom the wingtip will have to stick fout of the wing a bit. Unfortunately I have hacked it up enough that I either have to glass it up or get a new tip. Any thoughts on the tips?

Bryan, if you go to my Expercraft website, wings, October 2014, you can see the results I got. The fiberglass tip extends past the skin to an acceptable +/- 1/4" and was fairly consistent around the whole tip.
Correction..I looked at my wings again. The tip is even with the skin on the top. On the bottom the tip extends past the skin 1/8".

Thanks guys. Looks like I have some fiberglass in my future. Now can I use the bondo brand stuff I bought for Matthew's hovercraft or is it off to Spruce again?

For the small amount of filling I used Bondo lightweight filler from Walmart. Bondo is heavy compared to micro-balloon and epoxy so you don't want to use it to fill large areas but small areas like wing and tail tips are ok.