Onex Build Status and Completion Photos

[Onex11]

Hi Mike,

For myself, I believe that the spar option is a must unless you are equipped with the right tooling and equipment. The workmanship of the spars is really professional and flawless. I wanted the fastest route to completion so I choose all options. The Aerovee assembly will be enough of a challenge for me (tweaking and fine tuning). It is a personal position, the main thing is to have fun...

[Mike53]

IMG_0705.jpg (110.87 KiB) Viewed 25631 times

I bent a part this evening :mrgreen: so I can now say "Yay I started".I will be' Tail end Charlie' for team Canada me thinks.
Mike

[chris]

Looks good. I'm sure you are happy to get started.

Which bending method did you use? Clamp and beat it method, 2 ton press like David, or some other creative way with your cabinet making tools?

[Mike53]

IMG_0703.jpg (122.59 KiB) Viewed 25578 times

IMG_0702.jpg (140.87 KiB) Viewed 25578 times

Looks good. I'm sure you are happy to get started.

Which bending method did you use? Clamp and beat it method, 2 ton press like David, or some other creative way with your cabinet making tools?

I bought a 1 ton press and used a pipe extension for more leverage .With a 2 ft. extension on the handle I think my wife could bend it quit easily.The best tool I have bought so far is the pneumatic riveter.Well worth the $100 .I tried the manual riveter and figured if I had to do the whole plane with it I would look like Popeye by the time I was finished :?

[onex28]

It's been so quiet here that I will post a photo. I'm waiting for tail tips so I can close up the tail feathers. I don't like to rivet until the entire assembly is complete. Since this photo I've riveted all I can on the fuselage and have installed the motor mount angles. Waiting for backorders to move forward and the garage is getting colder! Ready to get it on the gear and put the main spar in. Am I the only Onex builder in MN?



Uploaded with ImageShack.us

[Mike53]

Looks like a plane,which has to be a great motivator.All I have is the tail and thats like having a prop on the wall.It's nice but there is just too much missing :(
Mike

[Onex11]

Its now time for an update. I am at the 300 hrs. milestone and I have decided to go for the UL category (it is OK here in Canada) so the tail part was completed (no need for inspection).

ONEX0021 Bird eyes view status after 300 hours (see pictures);

DSCF1328small.jpg (125.15 KiB) Viewed 25459 times

DSCF1330small.jpg (129.86 KiB) Viewed 25459 times

DSCF1332small.jpg (114.87 KiB) Viewed 25459 times

Rudder 100% completed
Ailerons 80% counterweights were B/O
Flaps 80%
Elevator 95%
H stab 100% skin installation done
V stab 100% skin installation done
Fuselage tail cone 100%
FWD box 100% and attached to the tail cone
Inboard wings 10%
Outboard wings 80% skin installation left
Seat and landing gear installed

One of the wing could not be completed because I ran out of CCP-48 rivets for the ribs. I also had major problems with the folding wing mechanism and I am waiting for Jeremy's input. It is not as easy to rig it as depicted in the drawing. I have probably ruined the 4130 steel plates of the inboard spars. I need to order new ones since the pin holes are now oversize and on the left handside offset by .060 in. I am still very happy with the Onex construction project except I am frustated to have made mistakes on the folding wing rigging. Well I am a first time builder :oops: .

[GOIX]

Hi Rheal ,

Are the problems with the wing fold mechanism something that all of us builders will experience ? What did you do wrong or would do differently ? Excellent progress !

Marc

[Onex11]

Hi marc,

I am frustrated because I almost made the same mistake on both sides. The explanation on the drawing is misleading (not complete) for a beginner. I have started with the LH and screwed it. The only way I can imagine being able to use the reamer properly, is to have the inboard end wing ribs removed. The guiding block shall also be removed leaving only the inboard main spar in place for wing rigging. Otherwise there is no room to properly use the reamer!

The RH rigging (done second) would be OK but I can feel a little loose in the wing because the main spar bottom hole is enlarged a little (.003in). The pin penetration problem is the same as explained below on the LH.

The problem on the LH is much worst; the pin assembly is shifted because the hole locations on the 4130 plates are offset (see pictures 1301-1302-1303) therefore the lever is out of alignment. Please note that pic 1301 shows the distance (.650in) of the outboard spar bottom hole from the edge, yet the distance (pic 1302) of the main spar hole is offset creating the mismatch of the lever (pic 1303). In any case, I now have ruined the 4130 plates holes on the LH. Please note that with the spar option, the holes come pretty much near the final size not 1/4in as mentioned on the dwg (at least on the outboard spars) and that does not help since there is no room for error. My top main spar bolt holes are OK. I also noticed that when all the bolts are tightened, the wing is hard to rotate up and down. Should there be a minimum gap? I noticed that the demo plane was easy to rotate did they used some lubrification? The rear spar slot is also very tight when the bolts are tightened and prevent the wing from closing in place properly.

I spent much time thinking about all this and the only solution that comes to my mind is to replace the 2X 4130 plates. At least on the LH as the RH might be OK if I use a larger reamer and a larger diameter pin (the lever is well aligned). This is overall the hardest part of the assembly up to now.

Questions raised to Sonex; what is the cost and delivery time for these 4130 steel plates and new guiding block (LH)? What is the maximum concentric play allowed on the locking pin holes? Should the wing be tight without any play vertically (on the drawing there is no tolerance)? Should the locking pin penetrates more (barely being supported by the AFT plate)? If yes, should the guiding block be countersunk to allow more penetration?

I hope we will all learn from my mistakes...

DSCF1301sm.jpg (119.83 KiB) Viewed 25432 times

DSCF1302sm.jpg (116.86 KiB) Viewed 25432 times

DSCF1303sm.jpg (122.88 KiB) Viewed 25432 times

[Onex11]

DSCF1342sm.jpg (115.5 KiB) Viewed 25327 times

DSCF1336crop.jpg (68.32 KiB) Viewed 25327 times

DSCF1333sm.jpg (120.35 KiB) Viewed 25327 times

Hi All,

This is how it looks after having using the countersink approach on the guiding block (opposite side). Much better, now the pin is being supported by the AFT plate see pic. Note that the lever now butts the bottom spar web. I feel much better about this part of the project.