Bending Rudder Drive Horn

[BobLewis]

New builder that just started a Waiex B and I'm trying to make the 5 degree bend in the rudder drive horn. Any wisdom for a method to make a clean bend on this part?

Thanks!

Bob

[Bryan Cotton]

Bob,
I have a few pics on my build thread like the one on this page:
viewtopic.php?f=39&t=578&p=6035&hilit=Arbor+press#p6035

1) Choose a big honking bolt to give you the proper bend radius. Saw off the head or threads if required. You can use any round steel rod.
2) Make a jig. I used two pieces of oak screwed to plywood. I set them apart by the diameter of the bolt. This works for the angles we need.
3) A line down the middle of the gap is helpful for alignment.
4) I use scrap screwed down to the oak to prevent the part from twisting. This is important especially on the odd shaped parts!
5) Bend away! It is better to not bend enough, and need another go than to overbend and have to unbend. But, we have all done it somewhere I bet.

[BobLewis]

Thanks for the pics Byran. I had already tried something similar with marginal results, needed to beef everything up to keep the jig from bending instead of the part. Just wondering if someone had come up with a different solution. Whoever said building an airplane is supposed to be easy? :D

BTW, I like your assistant builder. I had one on an RV project but now he's an engineer in Denver and not much help even after the RV was sacrificed to the tuition gods.

Thanks for the help!

Bob

[markschaible]

Also, check-out the video at: http://www.sonexaircraft.com/support/vi ... late_stock

The Sonex Video Tips page linked above cover just-about all of the basic metalworking techniques needed in the project.

[dtibbo]

Also, check-out the video at: http://www.sonexaircraft.com/support/vi ... late_stock

The Sonex Video Tips page linked above cover just-about all of the basic metalworking techniques needed in the project.

They've updated the link, in case anyone else is crawling these threads years later. The videos link to EAA Hints for Homebuilders, but it's a great compilation of Sonex-specific tips.

https://www.sonexaircraft.com/video-tips/