SonexBuilders.net

Hi all,
Does anybody have any tips for mounting tail tips? Or pictures? I am wondering how you aligned them and how you transferred pilot holes from the skins to the tips ( for you kit builders).

Hello Bryan,

I don't remember which page of the plans its on, but I believe there is a plans page that shows how much of a "notch" must be cut out of the back edge of the tail tips for ruddervator clearance. I cut that out, but before adding the reinforcement rib into the fiberglass tip, I fit the tip. In order to do this, the fiberglass tip fits inside the tail skin and it will sit on the outermost rib. Once seated, i used the skin as a template to pilot drill the holes through the fiberglass. One pilot drilled, make sure the ruddervator has an appropriate gap, trim as necessary, then you can install that rib reinforcement into the fiberglass tip.

It''s completely up to you, but you could also consider painting the tip prior to final instillation. Have fun...your build is looking great!

This is a Onex, don't know if it is applicable for the Waiex. This is how I did the tips.
http://onex-svingenb.blogspot.no/2013/1 ... -tips.html
http://onex-svingenb.blogspot.no/2013/1 ... -tips.html

To get the holes aligned I used a old home made hole duplicator. Eventually I drilled too much of the notch in the duplicator. Instead of fixing it right away I used a 12" #40 drill and drilled pilot holes from the opposite side, which was much faster and easier by the way (if the 12" drill bit haven't been so dull).

That, and other drilling experiences made me order a Christmas gift from my wife: a Drill Doctor 500X from ACS :-)

I think I see I made a mistake. I thought the pilot holes outboard of the last rib were for mounting the tip. It seems like it should have picked up the tip rib holes too. Whoops, I already have rivets there. I had planned on final install after paint. Also, I like the idea of drilling through with a long bit.

Mine is a Sonex so cant help with waiex alignment advice.

To help with inserting the tip between the rib and skin, I suggest not riveting the last couple of the outermost spar rivets until the tip is on for keeps.

Line up and fit with control surfaces installed. I wasn't happy with the fit of my rudder tip and later removed to adjust and refit.

I suggest aluminium rivets on all fibreglass tips. It will help make things easier later on when removing to repair hanger rash :x . My tips are riveted on with aluminium rivets only now, I originally installed all tail tips with stainless rivets and will never do that again.

Steve
Sonex 892 VHZSX

I looked at the plans, it looks like the tips do not pick up the rivets in the rib. Panic over.

I do see another issue though. My skins have a rounded leading edge as riveted on, and the glass parts are more tapered. Had I known I would have squeezed the leading edge down before I riveted the skins. Any other Waiexers had this issue?

Bryan. Looking at the photo the attachment of the tip on the sonex is nothing like on your waiex. On the sonex the tail tips are sandwiched between the rib and skin making them a B*##@ to fit. Is it just a waiex thing or is it a change for all sonex aircraft?

As for the tips not fitting perfectly I think that is normal. All my fibreglass tips including the wingtips needed work. The rudder was the worst requiring major surgery it had a horrible twist and a bulge at the front.

Steve 892

I struggled trying to fit the tail tip under the skin and eventually gave up.
I decided to do a common mod which is instead of trying to squeeze the tail tip between the skin and tip rib, just insert an aluminium “lip” and attach the rib to that, you then just need to trim the rib a bit more obviously because it does not go under the skin anymore.
Here’s are some pictures showing how this was done:




Many people have done this mod, also, I decided to rivet my tail tip to the lip but this mod also allows you to use nutplates with metal screws instead to attach the ribs to the tail, this way you would be able to remove the tips very easily.

Ryan of Waiex 197 and Kerry From Sonex both pointed out, nearly at the same time that the glass tip goes inside the skin but outboard of the rib. This is much like the mod that Michael mentions. Glad I asked and was made smarter!