Back to SONEX October 2012
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cutting pins and reassembling the lead mold for the second casting. I
finished assembling the mold and re-casted the second weight. I used the
torch to melt and cast the second weight. While that was cooling, I made
an aileron former blocks from 1" and .25" composite-chip board.
after an 8 Day Business trip to the east coast. I inspected all of
the rivet holes of the Aileron Ribs and filtered out all of the Ribs
that had holes in question. I went back with the Calipers and found 3
aileron ribs that I thought should definitely be remade and
re-drilled.... With a wider flange. Once the rib inspection was
complete, I went to the CAD Station to Draw the Ribs, New Ribs w/ wider
flange, and Sketch up former blocks to make the new Ribs.
Slow Night :-( I
finished disassembled the first lead casting. I removed all but 1
aluminum pin (it became stuck). I cleaned the casting.
Started work on
a mold to pour new Aileron Counterweights. I used aluminum angle and a
flat plate. I drilled and clecoed the angle on and drilled holes for
Hole Saver posts.
on the Lead Counterweight Mold. I used the Oxy- acetylene torch to melt
the lead down into the mold.
working on the elevator, performing a final debur operation on all rivet
holes. Once complete with debur, I fabricated the Cable attach
plate (for the Trim Tab) and mounted it to the left elevator drive rib.
This was a late
start / slow night, but I was determined to get something done! I
decided to fabricate the trim tab. I marked it per the drawing,
rough cut it on the bad saw, drilled the critical holes, bent it on the
break, and then sanded and polished it up nice n' perdy.
*** I think I my bend
radius is too small and might be prone to cracking. Before I rivet
the elevator together, I think I might remake this part with a larger
bend radius :-/
I began the
night by dis-assembling the elevator and inspecting the rib holes.
I found that some holes on the drive rib were not quite on centerline.
All holes were off to the inside of the flange and it is not yet known
how critical this offset will be (I Hope I'm not giving myself away here
by posting this! :-P) I deburred all ribs/skins, and began
updrilling the holes in the left elevator assembly.
I continued work on the elevator
assemblies. In an attempt to mitigate the extent of the
off-center-line holes, I used a file to bias the updrill to a more
desirable location. This seemed to work, in theory as it did not
move the hole closer to the flange edge. I will consult the
experts before finishing this assembly as to what my options may be.
Pleasant Distractions: Airplane flying, especially
with a new lovely Co-Pilot is always an acceptable distraction from airplane
My Co-Pilot, Kristen
A gorgeous day on Catalina Island
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