Oct 15, 2022     Prepare Wings for Transport - (3.5 hours)       Category: Wings

Prepared wing pushrods and spoiler cables for transportation and storage. Plugged wing root-end entry points against intrusion from animals or insects.

  May 16, 2021     Main aileron pushrod storage - (2.3 hours)       Category: Wings

While removing the main aileron pushrods (XNB-W07-08) to better enable storage by covering the lightening holes with 3 and 4" plastic mailing tube caps, found the port wing rod end bearing bolt was an AN3A-12 rather than a drilled AN3-12. It took a surprising amount of time to gently remove the incorrect bolt without putting undue force on the idler. Resorted to using a spring-loaded center punch to encourage the bolt to back out of the assembly by repeatedly punching the bolt center. Replaced the bolt with AN3, torqued the nut to 3.5 N, and installed a cotter pin to both port and starboard idlers, leaving the main pushrod rod ends in place on both wings.

  Apr 11, 2021     Complete Rework of Port Aileron Hinge - (1.2 hours) Category: Wings

Several inches of excess length on the inboard hinge pin permitted enough length to flattened the end somewhat with a hammer on a anvil. Repeated hammering on the end widened the pin end enough to be very snug in the hinge knuckles. Chucked the opposite end of the pin in a battery powered hand drill and used the flattened end as a reamer to open the clearance of the hinge knuckles slightly (tip learned at Jeff Shultz firewall forward seminar).
Same treatment to the outboard hinge knuckles. Cut and bent the inboard hinge pin. Pin fit for inboard and outboard hinge pins can be inserted freely, but remain snug.
Sanded areas of primer to smooth pebbly surface. Added lightweight filler to close several holes in aileron skin.

  Apr 06, 2021     Rework Port Aileron Hinge - (1.5 hours)       Category: Wings

Removed the single 72" 0.045" length of piano wire hinge and replaced it with three standard length hinge pins as configured previously on the starboard aileron. Cut 2" of hinge knuckles (4) with a hacksaw blade as the insertion point for the two inboard hinge pins. Trimmed the outboard and middle hinge pins to the same length.

  Nov 14, 2020     Missing rivet - (0.1 hour)       Category: Wings

Installed a missed rivet in the aileron hinge.

  Nov 08, 2020     Rodent cover - (0.5 hour)       Category: Wings

Constructed a metal cover to block rodents and insects from entering the interior of the wing. Cut a piece of 0.025" 6061T6, bent tabs around the edges to stiffen. Attached to wing rib with a Cleco. Bending didn't work our very well. Not an effective cover. Back to the drawing board for other solutions.

  Nov 08, 2020     Filler prior to sanding - (0.6 hour)       Category: Wings

Mixed some West System epoxy with lightweight filler and thickener. placed thickened mixture into the wingtip. I anticipate that in sanding the fiberglass to match the wing contour in this area, the fiberglass substrate may get sanded enough to cut through to the filler.

  Aug 09, 2020     Open rear spar anti-rotation pin inspection holes - (0.6 hour)       Category: Wings

The rear spar anti-rotation pin hole (still in need of reaming to final size) inspection hole were too low to put a reamer through from the rear. Using a step drill as a mill, extended the port and starboard holes upward. Used a bastard file to smooth to an ovaloid shape.

  Jun 25, 2020     Aileron fairings - (2.2 hours)       Category: Wings

Ordered two ABS-C01-04 Aileron Pushrod Fairing - ABS Molded from Sonex rather than cut and shape two fairings from sheetmetal. Used a bench sander to remove/melt the ABS flashing from the fairings. Waited for the flashing to cool then broke off larger pieces. Shaped with sander, and finished with a file. Drilled five holes for nutplate locations, transferring the holes to the wing skins. Dimpled skin and installed five #6-32 nutplates on the port wing.
When attempting to reinstall the port aileron pushrod, it was found that the central nutplate contacted the pushrod, interfering with smooth operation. The central nutplate was removed. Consequently only four nutplates were used on the starboard side aileron fairing attachment.

  Jun 25, 2020     Aileron Pushrod Linkage - bearings - (0.8 hour)       Category: Wings

Installed spoiler bushings XNS-W37-07 in Aurora bearings. Removed incorrect dual control pushrods. Installed XNB-W07-06 -01R/01L main push rod assemblies, torqued and checked movement. Did NOT install cotter pins.

  May 31, 2020     Rivet Starboard Aileron Hinge - (3.3 hours)       Category: Wings

Cut and bent a piece of angle to be used to safety wire interior aileron hinge pins. Clecod angle piece in place, ensured hinge alignment, installed 116 CPP-42 rivets, leaving off two on outboard end. May construct tab for wiring pins at outboard side.

  May 30, 2020     Connect Aileron Pushrod Linkage - (4 hours)       Category: Wings

Worked through the 2D auxiliary details of drawing XNS-W07 to arrive at the correct part stack-up for linkage connection between aileron bellcrank and idler. A simple exploded diagram with parts orientation would have been helpful. Connected main aileron assembly. The pushrod is incorrectly identified as XNB-W07-06 in drawing but supplied part is SNX-C05-05 aileron pushrod, dual stick. Need to order 3 additional XNS-W37-07 spoiler bushings as Sonex only supplied 7 with kit.

  May 30, 2020     Trim Bronze Linkage Bearings - (1.5 hours)       Category: Wings

Trimmed additional SYMMCO SF-610-6 bearing barrels on mini lathe. Found that a length of 0.290 inches is a good starting place for the welded aileron pushrod. Trimmed several too short. Machinists blueing doesnt stick to the Oillite bearings. Used a parting tool in the mini lathe, chucked the barrel end, supporting flange end with center. Thin bronze flash left on workpiece after parting tool breakthrough. Broke bronze with a small part of diagonal cutters. Filed flashing. Countersunk bearing ends with deburring tool.

  May 29, 2020     Trim Bronze Linkage Bearing - (0.6 hour)       Category: Wings

Sprayed blueing on sleeve of SYMMCO SF-610-6 bearing barrel. Stacked bearing, welded pushrod, and SYMMCO ST-1020-2 thrust washer stacked together. Used a 0.015" feeler gauge for distance and scratched blueing with scribe. Took apart the stack, but the blueing scratched or wiped off the barrel, leaving the scratched blueing line indistinct. Chucked the bearing in a mini lathe and parted the bearing, long by a little over 1/8". Back in the lathe but wouldn't center chucked on flange end. Scored barrel and filed excess.

  May 17, 2020     Inspection ports and port aileron linkages - (4.5 hours)       Category: Wings

Shortened the inboard hinge pin by 1/4 to 3/8 inch on starboard aileron to eliminate overlap with middle pin end.
Added 12 #6 nut-plates for inspection ports, two per port. Primed inspection port covers.
Worked on port side wing aileron to bellcrank bearing and deciphering the bellcrank to idler bearing stack drawings.

  May 10, 2020     Aileron Linkage - (2.8 hours)       Category: Wings

Work on connecting linkage and pushrods for starboard wing.

  May 10, 2020     Aileron Linkage - (2.8 hours) Category: Wings

Work on connecting linkage and pushrods for starboard wing.

  May 03, 2020     Starboard aileron hinge - (3.8 hours)       Category: Wings

Divided starboard aileron hinge, inboard half, into thirds. Removed two outboard aileron hinge knuckles 31" outboard with bare hacksaw blade. Smoothed cut knuckle edges with Scotchbrite wheel. Cut hinge sections into approximate thirds. Marked un-drilled middle section with a marker through outboard #30 holes. Drilled #40 holes over ends and thirds. Clecoed hinge section to wing, aligning hinge segments with hinge pin. Trimmed hinge pins to length, each approximately 31" long. Put a point on the free end of the pins with Scotchbrite wheel to ease hinge pin installation. Three hinge pins, two installed at 31" mark, one inserted inboard and the other outboard. Third pin installed from wingtip inboard.

Cut the long hinge pin from the original aileron hinge setup to a 36-1/2" hinge pin for use in the top wing tip attach hinge.

  May 02, 2020     Finish starboard wingtip attachment - (3.8 hours)       Category: Wings

Sanded wingtip edge to alignment markings. Reattached and updrilled tip/hinge holes to #30. Disassembled and deburred hinge rivet holes. Reattached tip to wing and riveted with CCP-42 rivets.

  Apr 26, 2020     Starboard Wingtip Attach Hinge - (3.5 hours)       Category: Wings

With attach hinge halves connected, aligned top and bottom tip attach hinge with wingtip. Alignment placed fiberglass tight against the wing skin. The edge will be trimmed to 1/16" gap later. Marked a point mid-span on each, drilling a #40 hole through fiberglass 1/4" from the edge. Pinned with a Cleco. Clamped hinge ends to fiberglass tip. In middle of wing tip. drilled a 'starter hole' orthogonal with hinge knuckle to start the rivet fan. Marked in pencil marks 1/4" from edge to align rivet fan holes. Spaced 1" center-to-center on fan and drilled
Updrilled wing skin to #30. Deburred skin. Riveted inboard top and bottom attach hinge. Used 5 knuckle splice (36-1/2" total length) on top at aft end as done on port wingtip.
Refit tips tight against skin. Walked fan to fore and aft wingtip, drill, cleco, drill, clico.
Removed tips, marking the fiberglass at the hinge 'pockets' with blue marker. This will be the sanding line for obtaining the 1/16" gap per plan sheet SNX-W??.

  Apr 25, 2020     Inspection ports and tips - (6 hours)       Category: Wings

Installed two #6 nut plates per underside inspection port (x6) to replace the Clecos that had been holding the inspection covers. Will add another 2 nut plates per port after order with AS. Countersunk nut plate mounting holes, riveted with CCP-34 pulled rivets.
Completed up-drilling, de-burring, and riveted port side wing tip attach hinge. Cut 6' hinge pin to 37".
Aligned starboard side tip over hinge, drilled initial locating holes through wingtip and hinge.

  Apr 19, 2020     Port Wing Tip Attach - Bottom - (4.5 hours)       Category: Wings

Ordered acrobatics wing tips for initial fitting.

Mixed some lightweight Evercoat filler ($20) for holes in wing tip with extra used to fill wheel pant seam. Sanded filler and Cleco-d hinges to tip. Mounted tip to wing and up-drilled outboard side with #30 drill. Disassembled, deburred, reassembled and riveted outboard hinge using CCP-42 rivets. Repeat with inboard hinge.

Clamped and aligned top starboard wing tip attach hinge. Drilled hinge with #30 drill. Wing skin had been previously drilled and riveted for MS20257P hinge. Those rivets were drilled out and removed. Cleco-d hinge to wing skin.

Hinge pin much easier to install on extruded MS20001P hinges compared with rolled MS20257P hinges.

  Apr 18, 2020     Sand Port Tip Edge - (0.4 hour)       Category: Wings

Sanded fiberglass tip edge using a belt sander to remove 1/16" or so of material. Alignment line produced by tracing edge of attachment hinge. Sanded edge until just the line was visible.

  Apr 17, 2020     Drill Port Tip Attach - (0.5 hour)       Category: Wings

Completed drilling top attach hinge with rivet fan alignment and deburr of MS 20001-3 hinge.

  Apr 16, 2020     Port Side Tip Drill - (.3 hour)       Category: Wings

Continued drilling #40 tip/hinge mount holes with rivet fan.

  Apr 13, 2020     Drill Tip Attach Rivet Holes - (0.5 hour) Category: Wings

Aligned rivet fan on port tip (XNS-W17-02L) with several previous alignment holes with Clecos, used fan to direct 1" rivet spacing, 1/4" in from wing tip. Wing tip was aligned closer to wing skin to allow for sanding of tip edge to produce 1/16" spacing.

  Apr 12, 2020     Port Acro Cap - (4.3 hours)       Category: Wings

Identified inboard end of undersized (0.045) hinge wire on port aileron hinge. Used a drill chuck to hold hinge wire, using the drill to ease the wire in and out of the 73" aileron hinge. Marked, cut, and bent outboard end of aileron hinge wire.

Cut MS2001-3 hinge for top and bottom attachments to port side acrobatic wing tip. Cut five knuckles from the wing side and added back a six knuckle length to make the 36-1/2" length for part XNS-W21-04 upper tip attach hinge. Set outside of knuckle flush with wing skin, drilled #40 holes and Cleco'd hinge to wing on top and bottom hinges. Aligned port side acro tip to hinge, marked tip location with hinge. Marked 1/4" line from edge of tip for drill line. Clamped, Cleco'd tip to hinge, locating attachment locations along the tip.

  Apr 11, 2020     Wing Tip, Bottom Attach - (4 hours)       Category: Wings

Cut MS20001-3 extruded piano hinge to 35-1/2" for port and starboard wing tips. Aligned knuckles flush with wing skin, clamped, drilled, cleco'd, deburred bottom port and starboard wing tip mounts.

Had previously installed MS20257P5-3 piano hinges on a utility tip. Installing the hinge pin would stick on the last 2 or three rolled knuckles. Using the MS20001-3 knuckles provides a smooth pin insertion. Extruded hinge is $35 per 3' segment.

  Feb 18, 2017     Aileron hinge, polish wing experiment - (2.5 hours) Category: Wings

Received MS20257P3 piano hinges from Aircraft Spruce. I'm afraid that AS's S&H charges will be costly over the life of the project, particularly without a complete drawing set to determine how excessive the Xenos-A hardware kit from Wicks (http://www.sonexaircraft.com/eshop/cart.php?target=product&product_id=17544&category_id=442%22) for the B-model Quick Build kit.
Cut hinge to length (46-1/2"). Setup clamps on drill press to space #40 holes 1/4" from edge of leaf. Drilled 47 holes centering hole on hinge knuckle.
Deburred holes.
Spend an hour and a half polishing a section of the wing.

  Jan 17, 2017     Receive Wing Quick Build - (2 hours)       Category: Wings

Rented 26 foot U-Haul and met Partain's over the road driver Michael and his dog Bear. Transferred QB fuselage, wings and boxes in a large isolated parking lot 1/2 mile off the Interstate. Took two trips to transfer the QB kit to Hangar 40 at WV12.

  Dec 17, 2016     Factory Quick Build       Category: Wings

  Nov 16, 2016     Quick Build Progress       Category: Wings

Photos from Sonex showing quick build progress.

  Aug 08, 2016     Initial Purchase - (1 hour) Category: Wings

Initial purchase of AeroVee standard gear mount.

  Aug 08, 2016     Initial Purchase - (1 hour) Category: Wings

Initial purchase of Wing kit plus Quick Build service.