Roth Waiex #197

[Bryan Cotton]

Awesome!

[Rynoth]

Along with finally getting back to work on my project, I've also finally updated my blog with more details of my progress over the past month.
I've just completed 9 new blog posts, which I'll link here. If you want to view them all, just click the first link and hit the "next post" link at the bottom of each post. Otherwise you can pick and choose from this list which posts you want to see:

Engine Mount: http://www.rynoth.com/wordpress/waiex/2 ... ine-mount/

Tailwheel: http://www.rynoth.com/wordpress/waiex/2 ... tailwheel/

Main Landing Gear Legs: http://www.rynoth.com/wordpress/waiex/2 ... gear-legs/

Wheel and Brake assemblies: http://www.rynoth.com/wordpress/waiex/2 ... ssemblies/

Rear-Spar Carrythrough: http://www.rynoth.com/wordpress/waiex/2 ... -assembly/

Control sticks and mixer: http://www.rynoth.com/wordpress/waiex/2 ... -assembly/

Rudder pedals and flap drive tube: http://www.rynoth.com/wordpress/waiex/2 ... rive-tube/

Wing Rigging: http://www.rynoth.com/wordpress/waiex/2 ... g-rigging/

Flight control pre-rigging: http://www.rynoth.com/wordpress/waiex/2 ... ing-video/

[Rynoth]

Also, here is a link to a 4800x speed timelapse video I made showing 230 hours of building, starting from just after completing wing assembly, and ending with wing rigging after the forward fuselage assembly.

http://youtu.be/N3LEp_9SQto

[SonexN76ET]

Impressive video Ryan! Your plane is really coming together well. Keep on building! The experience is well worth it. Words can barely describe how exciting it is to fly a plane you have built yourself.

[Rynoth]

Brake system (with turnbuckle for tension adjustments.)

http://www.rynoth.com/wordpress/waiex/2 ... ke-system/

[gammaxy]

Your magnetic hole-location technique was pretty clever.

What did you use for the big 1" nylon washer called for between the brake handle and bracket? I ended up buying a sheet of nylon and cutting out my own washer since I couldn't find anything close at Lowes.

I went through the exact same process with first buying nylon rollers then getting metal ones. I ended up removing the center of the metal roller and filling it with JB Weld and drilling a hole so it still worked as shown in the plans. I was worried the JB Weld might crush, but it hasn't yet :-) Back-of-the-envelope calculations based on the advertised strength convinced me it should probably work.

Have you considered adding a 20 degree notch to your flap bracket? I end up using that setting quite a bit. I don't mind using 30 degrees, but I can hardly climb at that setting at gross weight. No big deal, just have to be prepared to take it out in case of a go-around.

[Rynoth]

For the 1" nylon washer I actually used a combination of 2 nylon washers... can't recall the sizes, but basically a little one (that matched the bolt size) that fit into a big one of the same thickness. I spent so many (frustrating) hours trying to source the parts for this assembly, I finally just decided to make it work. I too could not find the specific (plans) washer in any local store.

I ended up using a giant cotter pin to secure the metal screen door roller. It fit the hole and I'm confident it will hold the shear force.

As for the flaps, that'll be determined during flight testing I suppose. Easy enough to fabricate a new detent angle and bolt it on if I'm not pleased with how it is.

[Rynoth]

Prop hub assembly attempt #2 was very close, but no cigar. No matter how hard I pounded, I could not get the prop hub to go that last 1/32" in order to press firm against the oil slinger. Almost 2 weeks now I've been trying to attempt step #1 of the aerovee assembly but just can't seem to finish it off. At this point I'd definitely say that the pre-assembled prop hub is worth the extra $$$.

Crank was frozen for 18 hours, hub was heated to 450 degrees for 3 hours. I have to think that something physically kept it from going that last 1/32", because it got there with 3-4 whacks of a mallet and then just held firm. Will see if my hydraulic press has the muscle to get the prop hub off when it's on 99% of the way.

[Rynoth]

My new Turbo Aerovee build has certainly not gone without issues. I recently updated my blog which includes several issues I've encountered during my engine build. None of the issues I've encountered actually have anything to do with the turbo itself, only the aerovee kit.

The final link has been the most frustrating, as it appears I received 2 faulty heads in my Aerovee kit.

Turbo Aerovee Delivery:
http://www.rynoth.com/wordpress/waiex/2 ... -delivery/

Crankshaft Assembly:
http://www.rynoth.com/wordpress/waiex/2 ... -assembly/

Case Aseembly:
http://www.rynoth.com/wordpress/waiex/2 ... -assembly/

Aerovee piston bolts and shims:
http://www.rynoth.com/wordpress/waiex/2 ... and-shims/

Cylinder heads and valve rockers:
http://www.rynoth.com/wordpress/waiex/2 ... e-rockers/

CYLINDER HEAD ISSUES:
http://www.rynoth.com/wordpress/waiex/2 ... ad-issues/

[Rynoth]

While I've been awaiting resolution to my Aerovee issues, I've completed preliminary installations of my fuel tank and windshield.

Fuel Tank Fitting:
http://www.rynoth.com/wordpress/waiex/2 ... k-fitting/

Windshield Fitting:
http://www.rynoth.com/wordpress/waiex/2 ... d-fitting/