Brief Description: Ffit HS skin and cut fiberglass wing tips
Ffit HS skin and cut fiberglass wing tips: After riveting the HS frame, the skin would not fit in the area of the center trailing edge. I could not see any thing I did wrong that would cause the misalignment of the holes. I ended up making two shims .060 thick to be inserted between the rear mounting angle and the two bent angles that the inside ribs connect to. I can't see any way the holes would ever line up without the shims. After installing the shims and reinstalling and torquing the 8 AN3 bolts the skin fit well.
Before riveting the skin on I wanted to fit the end tips. It's easier if you can force or shove the tip under the skin about 1" which you can not do once the skin is all riveted. Once you get the tip lined up the way you want it, you can mark it and then trim the edge. I ended up removing 5/8" off the HS tips and 3/4" off the VS tip. The prepunched skin holes in the end ribs on the HS do not line up with the skin at all, same for the VS. Can't see any good solution so will probably end up with some oval holes in the tip ribs. Not sure why Sonex provides these hole in the tip ribs since you match drill the fiberglass tip under the skin and there is no way to really align any prepunched holes in the rib to the skin. Once I get the tips fitted I will rivet the skin and tips.
For the trailing edge of the tips where you rivet directly to the fiberglass, I bought white colored large head rivets from ACS normally used to install baffle fabric and they work very well on the tips, looks better than CCP42 rivets with washers under the head as some builders have tried.
