SonexBuilders.net

I had trouble getting the preformed end rib W04-10 to fit my aileron correctly. There was a gap on the top forward edge as shown.



I contacted tech support and included pictures of the issue, along with pictures of my measurements. I was expecting that I had somehow cut the aileron skin incorrectly. The reply I got back was make the rib myself to get a perfect fit. They suggested holding a piece of aluminum sheet against the end of the aileron, and tracing the outline on the sheet. Then draw the material for the flanges.

I'm sure this could be done, but since I already had the preformed rib that fit everywhere but the forward edge, I decided to pound if flat, and use it as a template. I traced this template onto a blank sheet, adding extra length to the forward edge.

This worked out great.

It was also suggested that I could try to re-bend the end that wasn't fitting. I tried that, but noticed that the aluminum was starting to crack as I re-flattened it; so based on my experience, I wouldn't recommend that.

Great job making it work! That piece is a tough one; there are a lot of angles right there. Yours looks great though!

I ran into the same issue on my aileron tips. I did end up cutting and bending the kit ribs, just had to be real careful on the bending, just enough to make it fit and get good rivets. Here's my log entry with pics, about 1/4 of the way down the page.

http://www.rynoth.com/wordpress/waiex/2 ... d-aileron/

I had the same issue with my Sonex and thought I screwed up the ailerons, lucky I stumbled upon Rynoth's website and saw the issue (thanks). The preformed ribs cracked when I tried to re-bend them. The first rib I made only a mother could love :) I asked Bob Mika for his opinion, he gave me a funny look and showed me a proper radius bend and sent me home with his bending break. It took a few more attempts but I'm really happy with the way they turned out.

Photos
https://app.box.com/s/jyzw4hv9dskxxlxeq0ma
https://app.box.com/s/p0wivq3a1hghddew1t87

Great timing on this post. I am just now getting ready to cut and bend my aileron skins and make the end rib. I have been wondering how I was going to make that end rib as it looked pretty difficult. The trace the outline of the skin should work well for me. I will let you know how it turns out. :)