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Michaels Sonex #145 log
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Date: 2-13-2014
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Number of Hours: 1.50
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Manual Reference: F14-08R
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Brief Description: Remaking the right forward wing attach angle
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After a lot of going back and forth on this, I've decided to just remake my forward attach blocks and forward fuselage angles. It’s a bit more time and effort but I feel more comfortable with this decision.
I know reaming out the holes to a larger size might be the easiest and fastest solution but I just can’t bring myself to enlarge the holes on the aft spars/blocks/angles/fuselage verticals since those are all good, the 3/8 bolt sits very snug in those so I'm not willing to risk destroying those as well even though the risk of doing that might be small.
Even the aft part of the forward blocks appear to be OK, the enlargement of the hole seems to be max 1/2" deep in the blocks if it’s even that. It's hard to say exactly how deep but it is clear the bolt is nice and snug on the aft side of the forward blocks as well and the angles the blocks are attached to are certainly not affected.
So I’m thinking about re-using the spar angles the blocks attach to, attaching new blocks to them and use the existing 3/8” hole in the angles as a guide to drill the holes through the blocks from the back on my drill press, probably using a 3/8” – 1/4” bushing in the angle to drill a pilot hole first.
I would then only have to put the wings back into the fuselage and drill the 3/8” through the forward fuselage angle from the aft side this time, possibly using a 3/8” – 1/4” again bushing to drill a pilot hole first here as well. Little risk of screwing that up (again).
Today I started re-making the first of the 2 forward wing attach angles, it's been a long time since I've had to use the bandsaw etc. to fabricate such parts from scratch, I thought I was done with that bit. Luckily I still seem to have the skills.
Anyway, I bent the bare angle to the required 86.1 degrees on my vice and then rough cut the part on the band saw, I also started sanding/filing down the edges. This is not going to be that much work after all, the only issue is that I don't have any more angle to make the second one, neither do I have the bar
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