Machined angle component upgrade

[gammaxy]

Let's say it was about 60 hours since there were some parts like the flap notches and canopy siderail that I didn't make until later in the project and probably several I had to remake.

Here's a picture I took after working no more than an hour or two each evening during January and February 2011.
http://imgur.com/GQQa1F6

I don't believe this is a superhuman pace and if I build another Sonex I'll definitely consider saving ~$2k and making these parts myself. It's part of what attracted me to the airplane in the first place.

Sonex says the machined angles save 200 hours. For me this seems a little high but not totally unreasonable, but nowhere near the 2000 hours mentioned above.

[Rynoth]

Gammaxy - you completed the $1700-1900 upgrade kit in just over 40 hours plus drill time??

I"ve completed probably 80% of all the angle components for my Waiex so far. I did not log the fabrication time specifically since I made them as I went, but there were a few times (main spar, fuselage side skins) where a lot of angle components had to be made and once, and I did essentially log the time exactly. Based on that and other parts, I'd say I've spent less than 60 hours making the parts so far. A safe guess for me to do them all is probably less than 80 hours.

The second half parts I made took probably 3-4x less time than the first half, just after learning the best techniques to do it. At this point I can make pretty much any part from angle, cut/drilled/deburred and ready to go in under 30 minutes. I've had to scrap probably half a dozen parts so far, but it appears I still have enough angle in the kit to finish without needing to order more.

I know the Onex has more of these parts, but 2000 hours is ludicrous. Even 200 hours is pretty darned slow.

[Rynoth]

It took me about 3 hours to cut the lengths for all 44 parts in this picture. After 38 hours of work, 31 are complete and I have 13 to go. This represents about half of the angles in the entire kit (all in the forward fuselage.) Most of these took a higher than average amount of time to make because they ALL have a lot of pilot holes, and very few had laser-cut skins to match (fwd fuselage side panels aren't pre-laser cut), so there was a lot of precision drilling to be done.

Ok apparently the forum isn't allowing me to attach a picture, so here's a link to my blog with pictures. From start to finish of this blog post it took about 28 hours of fabrication. (The first picture on the page is the one I referred to above.)
http://www.rynoth.com/wordpress/waiex/2 ... brication/

[SvingenB]

I think the machined angle components are well worth the money. There is no problem making the pieces but you will need a band saw, a drill press, a press to be able to make them efficiently and accurately. These things cost money as well, lots of money for quality items. They also takes lots of space.

[fastj22]

I would also add a bench top belt sander to the required items to make the angled parts. And a deburing wheel.

[Rynoth]

I would also add a bench top belt sander to the required items to make the angled parts. And a deburing wheel.

I don't have a belt sander but it would be a nice to have. I use 2 different scotchbrite wheels, a fine and coarse wheel. The coarse wheel is extremely useful for this, removing material faster than a vixen file yet able to work all the angles and curves.

I also think the upgrade is worthwhile if your budget allows it. I'm no scratch builder, but making the angle components (especially the ones that can be seen when the aircraft is complete) are a point of pride for me as well.

For me (at this stage at least) cutting holes in skins racks my nerves more than making angle components, and everyone will need to cut holes in skins.. I just want to impress that making the angle components is not (by any means) beyond the skills required to complete the aircraft in the first place.

[fastj22]

I bought a HF bench top sander for about $35 w/coupon I think. Its cheap, but works great. I just have the fine wheel. It works great for polishing up the angle but not so much as shaping it. The sander does that swimmingly. Even if you buy the pre-made angle, you will still find plenty of use for it.

[Rynoth]

I can definitely see how a belt sander would make quick easy finishing of ripped edges, and any other straight edge. My coarse wheel makes quick and accurate work of any interior curves (btw the wheel also cost me about $35), and serves to finish the straight edges as well with care. One or the other (or both for the low low price of $70!) is apparently enough.

As far as tool investment goes, I'm not sure any workshop would be complete without a scotchbrite wheel, drill press, and some sort of hydraulic or arbor press (plenty of stuff to finish, drill, and bend regardless of the kit you buy), so the only extra tool perhaps required for the angle components would be a band saw, which I bought used for $80 ($120-ish new). It's tabletop, and I just move it off the table when I'm not using it (same goes for the other tools.)

[Bryan Cotton]

Belt sanders are awesome. I miss the one at my old EAA chapter. I have an old dinosaur of one that I need to set up sometime. These days I clamp my handheld belt sander in the vise and use it like that.
Scotch brite wheels are like a little bit of salvation. You can finish edges so quick with them.
Building an airplane is a great excuse to buy many tools. I like having tools.
Though I am an avowed scratch builder, I bought the machined angle component kit (and the whole kit, plus prebuilt spars). They are pretty awesome. I have found a couple instances where holes don't line up, and I try to duitifully report that to Sonex so they might review and tweak as required. For those that don't want to spend the money, you can see plenty of examples right on our little community here of people making nice parts from raw angle stock. Go for it and be proud.

[Gibbsfamily1]

I rough cut all my angle pieces on my Sonex in 15 hours and another 5 removing stress risers. I drilled mine at installation. I cut everything on a Grizzly band saw with a 14 tpi metal cutting blade. 1/4 inch. Cut I'll butter. I would do it again.