SonexBuilders.net

Hi fellow Onex builders.
Has anyone had any issues with lining up all the holes around the rear fuselage
vertical assembly F20-02 ?
For me I can cleko the sides,and the top but the 2 holes in the lower mount
angle are off.
That is they do not line up with the matching holes on the lower longerons.They
are off by about an 1/8".
I can force them to fit but only by using a clamp and pulling it in line ,but it
is obvious the cleko's are being strained on the side closest to the bottom.
Kerry so far has no answer why ,he has passed it on to Jeremy and he is at a
loss also.
If anyone has had to force them I would like to hear from you .
Thanks'
Mike

Mike, I've removed my labels and can't identify your problem area on the F20 print. But if it is the last bulkhead, I had a misalignment of the holes on the bulkhead flange that were off compared to the fuselage side skin. They were off by 1/2 to 1 3/32 hole. I clecoed the bulkhead top and bottom to the support angles that were clecoed to the longerons and drilled from the fuselage pilot holes to the bulkhead flange. Turned out fine. If this isn't your problem let me know what page your part is shown on.

David

Thanks David for the reply.
I think we are talking about the same bulkhead.It's labeled section BB on page F20.I have found I can force it to fit using a clamp to pull it in line but it is putting a lot of strain on the clekos along the sides closest to the bottom.I have asked Kerry if I can drill these up to the next size Rivet as this would take the strain off the rivets .
Still awaiting his response.
I suspect there are others out there who had similar misalignment issues at this bulkhead but just dealt with them in there own way.
Thanks again for letting me know you had some issues here also.It makes me think i didn't do anything wrong.
Mike

Mike this to confirm that we are talking about the same bulkhead. What I did was to cleco the F22-05 and F22-08 angles to the longerons first then cleco F22-04 bulkhead to those angles and then drill into the flanges of the bulkhead from the fuselage skin. I suspect you put the bulkhead in first which made the angle pilot holes not line up. I put the angles in first which made the flange holes not line up. It will work out but I preferred to not change the angle/longeron holes.

Yeah, thats basically the crux of it . Did you not wind up with elongated holes in the bulkhead flange towards the bottom?The bottom line is they were not match drilled holes all around that bulkhead.The only thing that will be attached to that bulkead for me will be the tail skid.
I just don't figure how just you and I had an alignment issue there and no one else :?:
Go figure :?
Thanks again,
Mike

Mike, here is a photo of how my bulkhead lined up against the skin holes. These are 3/32 holes and I suppose they were longated somewhat when I drilled to #30. But like you, mine is a nose dragger. I doubt that bulkhead is going anywhere and If necessary in the future I could go to a larger rivet in a couple of holes. If I was really concerned I could have drilled new inbetween holes. I'm sure we aren't the only two who ran into this situation.
David




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Hi David.
That looks exactly like my misalignment .Okay at the top and gradually going out of line by about 1 hole width at the bottom.
I am going to fill the holes I made in the lower longerons with an aluminum rod using my acetylene torch then use the 2 factory holes like you did and deal with the sides when it comes time to rivet.That way the bottom panel will not be a problem.I hope :?

I'm going through the same issue right now . I am dimpling and flush riveting my plane so solutions to hole mismatches are not as simple . I try to maintain the integrity of the thin flanges . I'll probably monkey with the holes in the bracket and longeron to make things fit .

Have you guys found any other serious mismatches ?

Marc
Onex 0024

GOIX wrote:I'm going through the same issue right now . I am dimpling and flush riveting my plane so solutions to hole mismatches are not as simple . I try to maintain the integrity of the thin flanges . I'll probably monkey with the holes in the bracket and longeron to make things fit .

Have you guys found any other serious mismatches ?

Marc
Onex 0024

Hi Marc .
How is the the only other Onex builder in Ontario coming along :?: I had a couple small issues with alignment http://onexmike.weebly.com/problems-avoided.html but nothing else so far that was as bothersome as the above problem you have just duplicated above.I'm working on the wing assemblies now and so far everything is as it should be.Mostly i'm slowed by hardware issues,in that there were revisions to hardware called out but the hardware kit I got was before such revisions,or maybe Im just slow but It gives me the excuse to rent the 150 and fly to Brantford and turn a .55 cent bolt into a $118.55 part. Economics was never my strong suit.
Cheers
Mike GXIX

Slowly , but gathering momentum . I have 2 weeks off now so the plan is to get in the hammer lane .
I've identified 4 former channels that have to be replaced but , for the most part, I'm impressed with the quality an accuracy of the kit .

There is actually another Ontario builder . He's an MDRA inspector in Cornwall named Pierre .

Keep up the good work on your website . I've referenced it a number of times !