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Joe's OneX #129 Project
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Date: 9-13-2013
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Number of Hours: 5.00
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Manual Reference:
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Brief Description: Fit root OB rib rear angle bracket
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I made a new set of OB root rib rear spar attach brackets. This time I did not drill the AN3 holes inthe short flange but I did drill the rib rivet holes. I cleco'ed the bracket to the rib and then wrapped the skin around the frame and cleco'ed it to the rear spar top and bottom. I then used a bushing in the rear spare AN3 holes to allow me to center a #25 bit and drill the mounting holes into the new bracket. I updrilled the bracket holes and reamed to 3/16" for the AN3 bolts. So, finally I had an angle bracket that aligned properly. I then removed it, deburred and riveted it to the rib and bolted it to the rear spar.... hopefully for the last time.
With the skin cleco'ed in place and snug up against the root rib, I was able to test fit the aileron and short push rod. As it turns out, I had to grind out about 3/32" from the lower inside location of the main spar pass through hole. Others have had to do the same so I hope Sonex will move the hole in future kits, once they have used up their current stock of premade spars.
Also, the rod exit slot in the lower skin needed to be extended towards the front of the wing. Assuming the down aileron movement will never go beyond where the counter weight would hit the top skin, I extended the slot 3/4" forward to provide rod clearance. I assume once the aileron stops are installed (some where), there will not be as much downward travel as I was creating therefore I may have been able to reduce the 3/4" extension slightly but I wanted to be sure it would not be a problem. I may have to modify the fairing for the rod.
Finally, when the aileron rod is centered in the slot left to right, the bearing on the end of the rod is further out board than the aileron horn. I found than adding one normal and one thin AN3 washers between the bearing and the horn, centered the rod in the slot. I know other builders have extended the aileron slot forward and had to add washers between the bearing and the horn to center the rod in the slot so perhaps Sonex will make these changes.
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New angle bracket
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Spar hole enlarged (upside down)
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Aileron rod slot extended 3/4"
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