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ONEX #54 Web Site
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Date: 1-7-2013
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Number of Hours: 6.00
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Manual Reference: F17
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Brief Description: Rivet aft bulkheads
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On dwg B04, detail C, it says to install the AN525-10R12 bolts through the skin, longeron and into the F22-05 bracket. Since the bottom skin goes on last, I don't see any way the nuts can be properly installed and tightened with all the skins in place. I installed the AN525-10R12 bolts and nuts to secure the bracket to the longerons. I enlarged the bottom skin hole at this location to 1/2" to clear the head of the bolt. Now the bottom skin can be installed with the bolts in place. The normal skin rivet spacing is still preserved in this location. See image 1.
As mentioned previously, the tail skid (or spring rod) is 5/8" OD and a sleeve is used to increase the 5/8" OD to 3/4" OD. This is supposed to provide a snug fit between the F22-07 brackets. However, the brackets are more like 7/8" apart, so with the sleeve there is still about 1/16" horizontal slop in the assembly. An AN960-416 washer on each side of the rod is about right to fill up the gap. This method was approved by Sonex (Kerry email) as a suitable fix. I think 7/8" OD x.120 wall material might be a better choice for the sleeve. Sonex is looking into this to see if there are any tolerance issues. I used JB Weld to glue the spacer washers in place on the brackets since it would be very difficult to get the washers in place while trying to install the bolt (image 2). Note: Don't install the clamping bolts as shown. Install the nuts on the inside, otherwise there is not enough room to remove the bolt when the washers are glued in place. As seen in image 2, I have also put a 5/8" hole though the right skin since the skid bolt is too long to install between the brackets and the skin. Unfortunately, the C/L of the bolts is about even with the top of the lower longeron, so a 5/16" deep "notch" was required in the longeron in order to fit the bolt in.
Installed the rudder pullies on the wrong side of bulkhead #1. They go on the aft side (1-13-13). Finished riveting all the bulkhead stations (image 3)
Installed the shoulder belt brackets.
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Bolt head clearance in bottom skin
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Spacer washers being glued with JB Weld.
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Bulkheads all riveted.
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