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Project: SpiritOfMudsuck -
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Empennage - (105)
Engine - (78)
Ext. Finish - (34)
Firewall Forward - (14)
Fuel System - (6)
Fuselage - (14)
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Interior Finish - (6)
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Builder Name:	Pete Dailey -

Project:	Sonex - Xenos-B Motorglider - VIEW REPORTS
Total Hours:	1506.3
Total Flight Time:
Total Expense:	$75148.03
Start/Last Date:	Jul 01, 2016 - No Finish Date
Engine:	Aerovee 2.1 Turbo
Propeller:	Sensenich
Panel:	MGL Avionics Explorer iEFIS/ECB/RDAC

Friendly URL:	https://eaabuilderslog.org?s=SpiritOfMudsuck

Home or Last Project Picture

Oct 27, 2020 Check dust cover fit - (0.2 hour)

Category: Empennage

Fit up stabilator dust and weather covers.

Starboard stabilator cover

Grommets

Port stabilator cover

Jul 26, 2020 XNB-T03: Finish starboard ruddervator skin closure - (1.2 hours)

Category: Empennage

Used twenty-some CCP-42 rivets in closing the starboard side ruddervator, inboard rear triangular skin flap.

Starboard ruddervator close up

Jul 26, 2020 RG-58 to BNC for ELT antenna - (0.8 hour) Category: Empennage

Stripped and crimped a three-part BNC/RG-58 connector for antenna connection at ELT. Removed ELT to judge how much antenna wire to allow the ELT to be removed from its mount and feed through mixer access panel. Removed and installed with one arm through the access space. ELT mount location feels accessible for later maintenance.

Jul 26, 2020 Nutplates for starboard ruddervator pushrod fairing - (1.3 hours)

Category: Empennage

Installed six, #6 nutplates to secure the starboard side ruddervator pushrod fairing.

Nutplate locations

Fairing in place

Fairings, rear view

Jul 19, 2020 Tail fairing fasteners - (2.5 hours)

Category: Empennage

Installed / reinstalled #6 nutplates to secure tail fairing. Reinstalled two of the three floating nutplates on the forward end of the fairing. Placed eight along the sides. Two on the starboard side were placed a little too close to the rivet line to be able to dimple the skin. Ninety-five degree heat took the life out of finishing installation of all the nutplates. May add two additional screws on the forward end to pull up the fairing to the fuselage skin.
This piece has taken more time and effort than anticipated.

#6 screws in place

Forward end fit

Overview

Jun 25, 2020 Make XNB-T01-02 fairing - (2.2 hours)

Category: Empennage

Marked the inside of a previously cut sheet of 6061-T6 with a fat felt-tipped marker. Clamped short end into a vise and used a propane torch to heat the work piece. Clamping the work piece by the short end was a mistake. As the workpiece lost temper, it wanted to fall forward which necessitated holding it in place until it cooled sufficiently to lay it on the workbench.
After the piece cooled, the wide end was marked with the dimensions from the trial work piece. Cutout marked at the wide end, and lengthwise tabs marked at approximately 5/8" wide. Setup in a HF bench brake, tabs were bent a bit more that 90 degrees. Very little spring back to the workpiece.
Formed curve in fairing by hand and by using the edge of the workbench. Tight fit at the wide end, trimming a bit on the forward edges helped.
Fairing needs some additional hand work to tighten the fit with the fuselage.

Removing temper with propane torch

Tail_fairing_fit - 12.jpeg

Fit to fuselage

Traced from plans and cut out

Marker indicator

Clamped by short end

Removing temper with propane torch

Jun 25, 2020 XNB-T01-02 Fairing - (0.7 hour)

Category: Empennage

Cut a trial piece of sheet metal approximately 12" x 4" to use as a trial fit to determine the dimension of the fairing fit with the stabilator installation. Marked up the trial piece with a marker, clamped in a vise, and heated the work piece with a propane torch until the marks changed color to remove the temper in the 6061-T6 metal. Bent one end past 90 with a hand brake. Set the piece in place to find the bend location on opposite side.
The bend angles on the trial piece were eyeballed to the shape of the opening. The HF handbrake produced a greater radius bend than had I used the HF bench mounted brake.
Forming the sheetmetal by hand to shape was much easier than standard T6 treated.

Trial fit

Trial fit with fastener locations

Trial fit

Trial piece Clecoed

Jun 19, 2020 Align starboard ruddervator pushrod fairing - (0.4 hour) Category: Empennage

Filed and aligned PVC pushrod fairing on starboard side. Drilled several #40 holes in anticipation of installing #6 nutplates.

Jun 19, 2020 Port side ruddervator pushrod fairing - (2.5 hours)

Category: Empennage

Located, drilled, deburred, dimpled, and riveted six #6 nutplates for securing port side ruddervator pushrod fairing.

Nutplate arrangement

Nutplates installed

Fairing installed

Jun 14, 2020 Ruddervator pushrod fairings - (2 hours)

Category: Empennage

Worked on sanding and aligning the ABS fairings to fit the ruddervator pushrod openings. Sanded to create matching fairings. Aligned the mounting holes to create identical hole spacing. Will be using machine screws and nutplates. Adjusted trial locations to find areas conducive to installing the #6 nutplates. Too high will interfere with the upper longerons, too far forward increases installation difficulty.

Hold together for sanding.

Trial fit

Jun 13, 2020 Replace Rudder Hinge - (4.5 hours)

Category: Empennage

Aligned and drilled holes in replacement hinge. Deburred and riveted with CPP-42 rivets. Middle two rivets pressed on tail post reenforcement, distorting the lay of the hinge. Alignments with rudder looked good during trial fittings with Clecos. Bolted the tailpiece in place, torquing to 5.5 Nm using 3 Nm for the bolt/nut and 2.5 Nm to overcome the nylock friction. .After final rivet and bolting of tail post, Hinge pin wouldnt go past half way down the hinge. Used a trick introduced in Jeff Schultzs FWF seminar to open the hinge pin hole slightly. Using a piece of hinge pin, the end was flattened slightly with a hammer on a vise anvil. Ran pin through hinge to the top and chucked the pin into a drill. While turning the pin, pulled it up through the hinge, opening the holes slightly. The opened holes allowed the original hinge pin the fit through the knuckles.

New hinge in place

Hinge in place.

Hinge riveted to tail post.

Tailpost bolted in place.

Jun 12, 2020 Starboard tail tip instrument lines - (1.3 hours)

Category: Empennage

Switched 3/16" dia vinyl tubing to the correct color. Blue vinyl tubing was incorrectly installed in the Total Energy probe port. Switched it to green. Looked at methods and positions to secure the pitot and TE lines from the tail into the 3002 AL tubing lines. Will likely use an epoxied on stud to secure a pair of clamps for the vinyl tubing.
Installed a BNC fitting to the RG59 antenna wire for the ELT.

StarbTailTip - 1 (1).jpeg

StarbTailTip - 1.jpeg

StarbTailTip - 2.jpeg

StarbTailTip - 3.jpeg

Jun 09, 2020 Replace Rudder Hinge - (2.5 hours)

Category: Empennage

Sonex released a Service Bulletin for all Waiex, Waiex-B, Xenos, and Xenos-B Aircraft on 04.29.20, reference XNS-SB-003 showing cracking of the tailpost channel. Photo of issue: https://www.sonexaircraft.com/documents/plan_sheets/Tail_Post_Channel_WIX-XNS-SB-003.jpg.

Coincidentally, I found several weeks ago the rolled knuckle hinge rather than the extruded knuckle hinge had been used in this application. Removed the bottom skin around the tail wheel to better access the nuts on the back of the tailpost bolts. Removed the tailpost bolts and tailpost doubler. Removed solid rivets and hinge. Cut new MS20001P3 hinge and aligned it on tail post channel. Added this area to the preflight checklist inspection items in the POH.

Difficult to reach the nuts, will take a look at removing a little material from the tailwheel reinforcement angles to open room for my arm to fit through.

Tailpost bolt removal

Fitting new hinge

May 31, 2020 Replace Rudder Hinge - (0.7 hour) Category: Empennage

Due to not recognizing the difference in hinge types, I had inadvertently installed a piano hinge with rolled knuckles (MS20257) rather than extruded knuckles (MS20001) as called for in the plans. Drilled out the rivets on the rudder hinge and began removing the skin under the tail in order to remove the AN3 bolts holding the Y and stiffener. Will remove the stiffener to access the hinge for removal, then reinstall.

Jul 04, 2018 XNB-T03: Finish Starboard Stabilator Riveting - (3.0 hours) Category: Empennage

Completed the top skin surface of the starboard stabilator.
Completed 95% of lower skin.
Drilled holes for tip nutplates. Countersunk solid rivets for nutplate mount.

Jul 01, 2018 XNB-T02: Set Stabilator Travel - (0.8 hour) Category: Empennage

Used the shoulder harness to hold the stick full rear. Spec asks for 11 degrees of deflection at full up.
Adjusted mixer ends to leave a little over half the threads showing. Adjusted pushrod length at the stabilator to provide at least 11 degrees travel up.

Jul 01, 2018 XNB-T03: Rivet Starboard Stabilator Skin - (2.3 hours) Category: Empennage

Riveting top side of stabilator, many CCP-42 rivets breaking proud of the head.

Jun 30, 2018 XNB-T02: Starboard Stabilator Category: Empennage

Install ruddervator hinge on starboard side stabilator. Initial hinge rivet holes were drilled centering the holes on the hinge rather than locating on center of knuckle as in plans. Second hinge set made from two shorter pieces and aligned correctly.
Stabilator tip cutout at 7/8" about 1/8" too much. Notched leading edge for instrument air port clearance.
Connected ruddervator pushrod with mixer.

Jun 03, 2018 XNB-T04: Install Tip XNB-T04-04 - (1.3 hours) Category: Empennage

Layout and drilled trailing nutplates with a diagonal orientation. May need to remove and reinforce one or both due to outside rivet proximity to edge.
Layout and drill rivet holes for stabilator tip XNB-T04-04. Cleco'd tip to fiberglass initially in two places on top. Moved tip trailing edge to minimize gap at trailing edge, then updrilled adjacent hole to secure alignment.

Jun 03, 2018 XNB-T04: Align and Rivet Tip - (0.5 hour) Category: Empennage

Deburr and rivet with CPP-42. One rivet created a small crack in the fiberglass.

Jun 02, 2018 XNB-T03: Port Stabilator Tip Alignment - (1.3 hours) Category: Empennage

Taped a length of aluminum angle to the leading edge of the stabilator to help align the leading edge and stabilator tip seam. Filed a cutout in the stabilator leading edge to clear the instrument air pickup port.
The cutout for the ruddervator was a little too wide due to neglecting to ensure the instrument air port was clear of the tip.

Jun 02, 2018 XNB-T03: Port Stabilator Nutplates - (2.0 hours) Category: Empennage

Upsized alignment holes in stabilator, dimpled #30 holes with 5/16' dimple die. Mounted 8 of 10 nutplates to the fiberglass tip with recessed solid rivets. The last 2 nutplates didn't allow for the mounting ear on nutplate enough room to mount parallel to edge. Plans indicate diagonal rivet mounting.

Jun 01, 2018 XNB-T04: Port Side Ruddervator Cutout - (2.5 hours) Category: Empennage

Cut fiberglass stabilator tip cutout with a wood blade on a battery powered oscillating saw. Started cutout with a 3/4" relief, with room for sanding to 7/8" relief.

Apr 15, 2018 Rivet Starboard Y and Stabilator - (0.8 hour) Category: Empennage

Riveted Y fitting to starboard side stabilator. Used mirror to verify rivet placement through inboard rib.

Apr 15, 2018 Close Port Stabilator Skin - (2.5 hours) Category: Empennage

Riveted port side stabilator skin, hinge, triangular insert. Triangular skin required material to be removed from the inboard side. Excess material prrevented ability to line up holes on trailing edge.
Installed ruddervator and set 15 degrees at mid ruddervator.

Apr 14, 2018 Rivet Port Y to Stabilator - (1.3 hours)

Category: Empennage

Used 1/8" drill to clean paint from rivet holes. Used CPP-44 for outboard (single Y) and CP-48 for inboard (double Y) rivets. None broke proud of head, though many needed two strokes to pull completely.
Was unable to properly locate bottom in board rib rivet. Will need to drill hole though Y to rib tab and rivet.

Xenos_Emp_Y - 1.jpeg

Xenos_Emp_Y - 2.jpeg

Xenos_Emp_Y - 3.jpeg

Xenos_Emp_Y - 4.jpeg

Xenos_Emp_Y - 5.jpeg

Xenos_Emp_Y - 6.jpeg

Apr 14, 2018 XNB-T01: Install Port Ruddervator - (1.3 hours) Category: Empennage

Ran length of 16 gauge through vinyl 'conduit' to stabilator tip for video camera. Riveted bottom skin trailing edge to triangular insert.
Cleco'd ruddervator hinge to stabilator. Attached stabilator. Installed bushing to adapt AN3 bolt in port pushrod

Oct 15, 2017 Fit Tailcone Fasteners - (0.5 hour) Category: Empennage

Fit washers and nuts to tailcone fasteners. AN3xx-5 is correct size, -6 need two washers.

Oct 08, 2017 Torque Forward Stabilator Spar Splice Plate - (0.5 hour) Category: Empennage

Torqued splice plate bolts to fuselage bulkhead.

Oct 07, 2017 Align and Bolt Stabilator Forward Spar to Fuselage - (3.0 hours) Category: Empennage

File port stabilator skin to minimize center gap (0.015") between stabilator forward spars. Aligned XNS-T02-02 Forward splice plate with forward spars. Drilled initial alignment with #40, updrilled to under 3/16 then reamed to 3/16". Drilled lower bulkhead/skin rivet to relieve shop head interference with bolt head.
Removed and deburred stabilator forward spar, including using a chip chaser between spar plates.
Installed bolts with washers and nuts, but did not torque to 5.5 nm - will get helper to assist.

Oct 01, 2017 XNB-T02: Prep Stabilator Attachement - (3.5 hours) Category: Empennage

Pilot drilled starboard side stabilator forward splice plate XNS-T02-02. Pilot drilled all exept outside lower hole which was unreachable with drill.
Updrilled top left hole to 3/8" and inserted bolt.
Filed left side skin which appears to prevent full centering.

Oct 01, 2017 XNB-F21: Complete Tailcone box - (0.8 hour) Category: Empennage

Riveted remaining tailwheel vertical angles. Replaced three rivets on the port side that didn't hold the angle tight to the skin.
Aligned and drilled spacer. Up-drilled tail cone skin and longerons.

Sep 30, 2017 XNB-T02: Fit stabilators to bulkhead - (3.0 hours) Category: Empennage

Drill rivets on old rear spar cap, replace cap drilling new holes for rivets. Dimpled spar and ribs where necessary, aligned and riveted replacement rear spar cap in place.
Drilled for skins and Cleco'd. Fit stabilator to tail and drilled Y-fitting holes. Disassembled and deburred.
Riveted recessed leading edge skin to forward spar cap.

Sep 30, 2017 XNB-T02: Fit stabilators to bulkhead - (1.5 hours) Category: Empennage

Aligned right side stabilator to bulkhead after determining the bolt head from the forward spar root rib attachment was preventing 1/8" of the spar attachment from centering. Used a 1/2" sanding drum to remove material from bulkhead/skin allowing full movement of the spar attachment fitting.

Sep 27, 2017 XNB-T05: Cut and shape replacement stabilator rear spar - (0.5 hour) Category: Empennage

Located and drilled hole with step drill to 1" diameter. Sawed two segments tangent with hole. Filed and deburred edges.

Sep 24, 2017 XNB-T02: Test Fit Stabilators - (1.3 hours) Category: Empennage

Test fit stabilators to tail cone box. Will remake right side stabilator aft spar as it was damaged by rivet gun when attempting to use an oversized rivet on outer rib.

Test fit left ruddervator to stabilator.

Sep 24, 2017 XNB-F21: Inspect Forward Tailwheel Mount - (0.3 hour) Category: Empennage

Inspecting the forward tailwheel mount and verticals determined that spacer XNB-F22-16 was neglected.

Sep 23, 2017 NB-T02: Port Stabilator Installation - (0.4 hour) Category: Empennage

Installed port stabilator with Clecos. Installed length of LMR-400 inside stabilator for future antenna mount in stabilator tip.

Sep 23, 2017 XNB-F21: Forward Tailwheel Attach/Verticals - (1 hour) Category: Empennage

Fit forward vertical angles to forward tailwheel attach angle. Removed and re-riveted right side angle to allow it to lay flatter against the skin. Additional rivet place on right side.
If remaking this assembly, I would have drilled the bolt holes in the tailwheel mount and matched the forward attach angle rather than drilling the holes in the attach angle first.

Sep 23, 2017 XNB-F23: Bolt Y Fitting and Tailwheel Mount - (1.5 hours) Category: Empennage

Bolted Y fitting, tail post assembly, and tailwheel mount using AN3 bolts with AN365 nuts with washers sized per drawing. Torqued nuts to 5.5 Nm.

Sep 23, 2017 XNB-F23: Bolt Y Fitting and Tailwheel Mount - (1.5 hours) Category: Empennage

Bolted Y fitting, tail post assembly, and tailwheel mount using AN3 bolts with AN365 nuts with washers sized per drawing. Torqued nuts to 5.5 Nm.

Sep 17, 2017 XNB-F21: Tailwheel Mount & Vertical Angles - (1.2 hours) Category: Empennage

Fit and drill rivet holes for left and right vertical angles mounting to tail wheel mount attach angle. Fit to tail-cone, drilled and deburred holes in vertical angles. Fit and drilled 3/16" dia tailwheel mount to angle holes. Riveted vertical angles to tail wheel mount attach angle.

Primed and painted tailwheel mount.

Sep 16, 2017 XNB-T04: Prep Starboard Stabilator Skin For Riveting - (3.5 hours) Category: Empennage

Dimpled leading spar with super-simple dimple ground on edge to fit sections where 'hockey sticks' are riveted to forward spar. Used squeezer to dimple outboard sections. Dimpled outboard rib at tip.

Cleaned skin interior with acetone. Primed interior surface with Duco Self-etching primer. Assembled with Clecos.

Sep 15, 2017 Dimple Forward Spar Skin - (0.8 hour) Category: Empennage

Dimpled skin holes for flush rivets in forward spar.

Sep 14, 2017 Updrill and Deburr Right Stabilator - (1.5 hours) Category: Empennage

Complete up-drilling and deburring of skin and substructure.

Sep 11, 2017 Fit and Drill Right Stabilator Skin - (1.0 hour) Category: Empennage

Sep 09, 2017 XNB-T04: Align and Drill Skin & Substructure - (1.0 hour) Category: Empennage

Drilled a representative sample of #40 holes across the underside forward spar, the triangular inboard patch, and several #30 holes in the underside trailing edge for temporary rivets.

De-riveted the #? rib to bend and move slightly for better alignment and filed the forward tab edge for better clearance with the forward spar. A slight bend in the forward tab centered the forward rib edge.

Flipped and removed top trailing temporary rivets. Cleco'd bottom trailing edge. Compressed and aligned top substructure.

More 'cautious' align/drill/examine then previous stabilator using 2x4 and webbing to compress. This method provides a greater opportunity to slightly adjust the subframe.

Outboard rib has a bit of cant to pull into vertical.

Sep 08, 2017 Updrill/Deburr Stbd Stabilator Skin - (1.5 hours) Category: Empennage

Up-drilled #40 to #30 except the forward spar which were drilled to 1/8" in anticipation of hole expansion from dimpling.

Sep 07, 2017 Align Stabilator Skin - (3.0 hours) Category: Empennage

Aligned stabilator skin on sub-structure. began with bottom outboard corner with edge of skin extending 3/4" from outside of outboard rib. Opened the instrument probe mount hole in leading edge and drilled the forward spar to outboard rib rivets to allow better rib placement.

Aligned top in aft outboard corner and drilled several rivet holes on top trailing edge. Installed temporary rivets in top aft edge to maintain alignment when inverted on workbench.

Sep 04, 2017 Deburr Y Fitting - (0.3 hour) Category: Empennage

Deburr mating section of Y fittings.

Aug 31, 2017 XNB-T04: Fit Right Stabilator Skin - (1.3 hours) Category: Empennage

Drilled 1/2" hole in skin for instrument probe. Marked outboard skin edge at 3/4" using the mark to trial fit skin to outside edge of substructure.

Aug 30, 2017 Deburr Y Fitting/Stabilator - (1.0 hour) Category: Empennage

Deburr holes on Y fitting and stabilator substructure.

Aug 29, 2017 Up-drill Y fitting attachement - (0.8 hour) Category: Empennage

Up-drill rivet attachment from Y fitting to stabilators.

Aug 27, 2017 XNB-F: Mount Y Fitting and Stabilators to Workbench - (1.0 hour) Category: Empennage

Secured Y fitting to workbench. Drilled several #30 holed through Y fitting and stabilator aft spar for Cleco's to attach right stabilator sub structure.

Aug 26, 2017 XNB-T05: Complete Right Stabilator Substructure - (3.8 hours) Category: Empennage

Make ribs XNB-T06-16,-17,-18. Rivet ribs to stabilator substructure.

Aug 08, 2017 XNB-T05: Prep Stabilator Ribs - (1.5 hours) Category: Empennage

Drilled and trimmed ribs for right stabilator.

Aug 04, 2017 XNB-T06: Remake Stabilator Ribs - (0.2 hour) Category: Empennage

Cut ribs #3, 4, 5, and root to length.

Aug 02, 2017 XNB-T05: Right Stabilator - (1.2 hours) Category: Empennage

Right stabilator structure; rivet forward spar.

Jul 15, 2017 XNB-F22-05R/L: Remake Vertical Angles - (1.2 hours) Category: Empennage

Remade left and right vertical angles. First set didn't align to the tailwheel mount attach angle well.

Jun 27, 2017 XNB-F25: Inspection Cover Installation - (1.5 hours) Category: Empennage

Experimented with countersunk fasteners and nut plates rather than sheetmetal screws. Dimpling cover for bugle head screw creates undesirable distortions.
Will likely replace cover and use std #8 pan head screws.

Jun 24, 2017 XNB-F23: Rudder Installation - (2.5 hours) Category: Empennage

Rivet together rudder hinge, channel, and fuselage. Connect rudder control cables to mixer. Add right side pulleys. Mark pulley location in cockpit.

Jun 17, 2017 Fit Tail Cone Parts - (3.0 hours) Category: Empennage

Drawing XNB-F21.

Jun 14, 2017 XNB-T05: Stabilator Structure Prep - (0.8 hour) Category: Empennage

File, sand, and Scotchbrite right stabilator spar cap edges to remove marks from laser cutting.

Jun 13, 2017 XNB-T05: Up-drill Right Stabilator Substructure - (1.7 hours) Category: Empennage

Up-drilled and deburred right stabilator substructure.

Jun 08, 2017 XNB-T04: Pilot Drill Stabilator Sub Structure - (0.8 hour) Category: Empennage

Tip rib location, drill pilot holes, evaluate ribs.

Jun 03, 2017 XNB-F22: Tail Vertical Angles - (1 hour) Category: Empennage

Layout, cut left and right XNB-F22-05 L/R vertical angles from SNX-Z03-04 channel stock.

Jun 02, 2017 XNB-T06: Stabilator Spar - (1.5 hours) Category: Empennage

Layout and cut right stabilator spars.

May 31, 2017 Trial Fit Y-Stack - (0.3 hour) Category: Empennage

Trial fit of Y-stack. Tailwheel mount a bit tight.

May 30, 2017 Up-drill Y Fittings - (4.0 hours) Category: Empennage

From aligned Y fittings, upper & lower attach tabs, tailwheel attachment, all but two #40 holes were drilled and reamed to 3/8". The fit of remade upper tab was unsatisfactory. Remade upper tab XNB-F23-02 and bent to 94 degrees.
Will fit XNB-F23-02 to the #40 holes in the tail cone, then mark and drill to 3/8" on the Y fitting/channel stack.
Lower attach tab hole a bit too close to the angle web. Filed a washer edge to permit flat fit of bolt head.

May 28, 2017 Trial Fit and Mark of Y stack - (2.5 hours) Category: Empennage

Drawing XNB-F23: Alignment and trial fit of Y, channel, and tailwheel mount components for drilling upper and lower mount tabs.

May 13, 2017 Tail Post Test Fitting - (1.5 hours) Category: Empennage

Drawing XNB-F23. Test fit tail post channel and Y support. Very tight between channel and Y stack. No room to Cleco the tail post channel for the purpose of aligning all Y sections, channel, and tailwheel mount. Will use -03 forward Y fitting for bolt hole alignment. Test fit port side stabilator briefly to check fit.

May 10, 2017 Remake Tail Tab Mounts - (2.3 hours) Category: Empennage

Drawing XNB-F23. Remade XNB-F23-02 -05 -07. Prior effort left dimensions too short by approximately 1/8".

May 08, 2017 Remake Upper and Lower Mounting Tabs - (0.8 hour) Category: Empennage

Drawing XNB-F23. Began cutout for F23-07 tail wheel mounting tab and -2, -.
Found the Y mounting tabs too short by 1/4 - 3/8" across the wide part of the tab. Began new 2" angle cutouts.
Using scrapped channel and clamps as a band saw fence helps maintain consistent cuts.

May 06, 2017 Test Fit Y to Fuselage - (1.5 hours) Category: Empennage

Drawing XNB-F23. Drilled out remaining 'red' rivets in tail cone to open area for installation. Test fit Cleco'd Y mount to tail cone. Remove a rivet to enable fitting top attach angle in tail cone.

May 04, 2017 Fitting Tailpost - (2.0 hours) Category: Empennage

Drawing XNB-F23. More tail post fitting to Y. Align to Y doubler, drill, deburr.

May 03, 2017 Fit Y Attachment - (2.5 hours) Category: Empennage

Drawing XNB-F23. Fit upper and lower attachment (-02, -05) to Y.

Apr 30, 2017 Y Tail Mounting Tabs - (2 hours) Category: Empennage

Drawing XNB-F23. Layout and cut XNB-F23-02 and -05 top and bottom mounting tabs on bandsaw. Step drill for 7/8" hole, bandsaw to open space for tailwheel mount.

Apr 23, 2017 Skin Left Stabilator - (11.3 hours) Category: Empennage

Drawing XNB-T03. Fit skin to structure. Deburr, used self-etching primer on skin interior. Dimpled leading edge rivets for CCC-42. Prepared hinge for ruddervator. Test fit ruddervator to stabilator. Test fit Y structural part to aft stabilator structure. Rivets a half diameter too close to Y in first half dozen inboard bottom trailing edge rivets.

Apr 22, 2017 Rudder Layout & Drill - (4.5 hours) Category: Empennage

Drawing XNB-T09. Rudder layout, drill, up drill, deburr, rivet.

Apr 22, 2017 Prep Stabilator Skin - (3.5 hours) Category: Empennage

Drawing XNB-T02. Prepared skin and structure for riveting. Cleco'd top and bottom sides. Up drilled top. Key factor in alignment was to correctly locate top outboard rear corner. Then worked top bottom edge. Hole for probe had to be expanded outboard slightly to allow for slight structure movement.

Used a ratchet strap and a 2x4 across the underside leading edge to bring skin to alignment on bottom aft edge.Alignment to aft channel edge and 3/4" outboard skin to outboard rib.

Apr 21, 2017 Rudder Cut and Prep - (3.5 hours) Category: Empennage

Drawing XNB-T09/10. Cutout rudder skin. As delivered, top and bottom were rough. Once trued to within 1/16", the forward height was 1/8" less than plans 12".
Trimmed ABS/fiber tip cap with bandsaw. Trim rudder drive plate cutout. Layout rivet locations on rudder skin.

Apr 20, 2017 Rivet Port Stabilator Structure - (3.5 hours) Category: Empennage

Drawing XNB-T03. Layout, drill, dimple (aft inboard under Y-plate), true, rivet, and install instrument piping and conduit on port side stabillator.

Apr 19, 2017 Prep Left Stabilator Structure - (3.8 hours) Category: Empennage

Drawing XNB-T06. Prepare forward spar and channel for riveting. Deburr, sand, smooth spar edges to remove laser cut marks and surface oxydation. Medium and fine emery and Scotch-brite. Marked outside of spar channel with rivet sizes. Rivet forward and aft spar caps to channel, with Cleco's in rib tab holes from inside to prevent riveting.

Apr 17, 2017 Fit Left Stabilator Structure - (3.5 hours)

Category: Empennage

Drawing XNB-T06: Fit, drill, deburr, Cleco left stabilator structure. Need to remake root ribs in 0.032" channel. Had used 0.025" channel.

Ruddervator

Tab connection

Structure

Ruddervator structure

3/8" air drill TOO HEAVY!

Holes for pitot, lights, antenna

Orthogonal alignment

Xenos_empennage_B - 46.jpeg

Apr 14, 2017 Stabilator Forward Spar Cap Bending - (1.5 hours)

Category: Empennage

Drawing XNB-T06. Used 20 ton HF press, 1" bolt, and wood blocks to bend stabilator Forward Spar Caps. Target angle is 14.3 degrees.

10 ton press over V-block

Bending radius w/1" dia bolt

Bending ruddervator

Apr 14, 2017 Layout Stabilator Structure - (5.0 hours) Category: Empennage

Drawing XNB-T05. Cut spars and layout ribs for what I thought was the right, but is now the left stabilator structure. Seem to occasionally visualize the incorrect view of parts from the drawing, particularly where the drawing view is not described (as in right underside). Align the tip end, squaring with the aft spar and measuring the length at forward spar intersection. Bent the right side forward spar cap, shown in next entry.

Apr 14, 2017 Layout Stabilator Structure - (5.0 hours) Category: Empennage

Apr 13, 2017 Rivet Ruddervators - (3.5 hours) Category: Empennage

Drawing XNB-T06: Completed drilling and deburring of left ruddervator. Aligned and riveted ribs, skin, and hinges. Inadvertently riveted left side hinge with end flush with outboard edge. Drilled out rivets and moved hinge to align inboard edge. The consistent one inch spacing due to the drilled aluminum ruler (see previous link) helped enormously in dealing with the error.

Apr 12, 2017 Ruddervators, drill & rivet - (2.3 hours) Category: Empennage

Drawings XNB-T06 -07 -08: Bent right ruddervator drive plate. Riveted drive plate to rib. Riveted right ruddervator.
Set and drilled 'used' hinge to left ruddervator. Updrilled and cleco'd left ruddervator.

Apr 12, 2017 Drill and Deburr Y Plates - (2.3 hours) Category: Empennage

Drawing XNB-F23. Opened and deburred 88 holes with #40 drill. Consumed 4 drill bits in the process. Combination of 1/4" Mac drill and drill press. Starter hole with air drill, then followed up drilling the stack with a drill press. Broke 2 bits in three plate stack.

Apr 05, 2017 XNB-T07 Ruddervators - (1.3 hours) Category: Empennage

Drill left side drive rib, rivet left side drive plate to root rib. Debur and reassemble right side. Wrong left side ribs (-04 not -03).

Apr 02, 2017 Port Ruddervator Fab, XNS-T07 - (4.0 hours) Category: Empennage

Markout, cut, deburred fit drive plate to left ruddervator.

Apr 01, 2017 Starboard Ruddervator - (2.5 hours) Category: Empennage

Drawing XNS-T07. Mark, cut, fit, drill, deburr right ruddervator.
Used Dremel rotary saw for diagonal skin cut and pocket. Abrasive 'metal' blade created a fair bit of heat. Cut had significant dross on edges. Tool was very controllable and enabled close cuts resulting in reduced filing effort.

Mar 18, 2017 Updrill Ruddervator for Drive Plate, XNS-T04 - (1.3 hours) Category: Empennage

Updrilled rivet holes to #30 in starboard ruddervator. Drilled out port ruddervator drive plate rivets and recovered riveted drive plate.

Mar 18, 2017 Drill Ruddervator Drive Plates - (1.3 hours) Category: Empennage

Drill and debur port and starboard ruddervator drive plate and root rib.

Mar 18, 2017 Drill Ruddervator Drive Plates - (1.3 hours)

Category: Empennage

Drill and debur port and starboard ruddervator drive plate and root rib.

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Mar 08, 2017 Bend Stabilator Tabs - (0.5 hour) Category: Empennage

Put bends on mounting tabs using a floor-mounted metal brake at Mallory. The floor brake gives better initial bend than hand brake which tends to round the tab behind the bend.

Mar 07, 2017 Mark Stabilator Ribs for Bending - (0.3 hour)

Category: Empennage

From plan sheet XNS-T03, marked fore and aft ribs for bending on brake.

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Mar 05, 2017 Deburr & Prep Fore Channel - (1.5 hours) Category: Empennage

After a 6 month wait for 0.032" channel parts from Sonex (two months after Quick Build delivery) prepared long edges of tail stabilator rib mounts. Remove dross and deburred edges on Scotch-Brite wheel.

Mar 01, 2017 ST-1 Probe Mounts, XNS-T03 - (4 hours)

Category: Empennage

Constructed and mounted ST-1 probe mounts for pitot and total energy probes.
- Layout and bend aluminum mounts.
- Probe diameter 1/2 inch
- 1/2 inch wide rivet tabs
- 1 inch probe mount
- Test fit mount.
Prep rib tip and probe mount with medium sandpaper for epoxy to 'bite'. Mould aluminized epoxy into ribbons, embed probe mounts. Compressed mounting bracket to extrude epoxy. Cleanup and rivet mount to rib.

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Probes attached to rib

Probe mount w/epoxy

Feb 26, 2017 Stabilator Ribs, XNS-T06,-03 - (4.5 hours)

Category: Empennage

Additional rib work to locate and drill access through ribs for probe (5/16" hole/AN931-3-5, 3/16" ID), conduit (5/16" vinyl tubing 9/16"/AN931-5 for lighting/video), and antenna cable (RG-58).
Tried using small flute bit on router table to cut the rib edges. Found that the 4041-T6 aluminum stuck and clogged the router bit.

Ribs

Router table with 1/8" birch guide

Router table

Feb 25, 2017 Study Tail Kit Plans, Stabilator - (1 hour) Category: Empennage

Tail Plans Arrived. Studied the materials and tools required for tail assembly.
From drawing XNS-T03 Stabilator Assbly, parts to fabricate a clamp to secure pitot and TE probe.
To purchase:
For attachment of fiberglass stabilator tip MS24694-SS Machine Screw, qty 10 left, 10 right
MS21047 Anchor Nut, qty 10 left, 10 right
SSC-34 Flush Blind Rivet, qty 20 left, 20 right
Need a countersink.
Grommet AN931-3-5, qty 21 right only for aluminum instrument tubing lines for Total Energy, pitot, and static pressure sense probes. Check requirement for a single like this ILEC mount: https://www.cumulus-soaring.com/ilec.htmf. Found this Article on Total Energy Compensation in practice: https://www.cumulus-soaring.com/ilec/TotalEnergyCompensationInPractice-Brozel.pdf.

Feb 09, 2017 Part Construction from XNS-T08 - (1.0 hour) Category: Empennage

Shape clips with file. Smooth edges on Scotchbrite wheel. Mark bend locations on forward spar caps, AKA 'hockey sticks'.

Feb 08, 2017 Stabilator Parts Construction, XNS-T08 - (1.5 hours)

Category: Empennage

Part -08R & -08L rough cut.

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Aug 08, 2016 Tail Kit Purchase - (1 hour) Category: Empennage

Initial purchase of Xenos tail kit.