Thursday 29 August 2013

Trip #2 - 3

Today, I worked with Keith to match drill the Y-Tail Doubler Strap supplied with WIX-SB-001 to the existing holes in the rear spar of the empennage. It was a good idea to remove the empennage from the fuselage. This job would have been impossible to do while the tail was on the aircraft.

After drilling the Doubler Strap, Keith and I proceeded to reinstall the tail on the aircraft. We noticed that the forward spars of the Y-tail did not want to sit flat on the fuselage. There is a little bit of twist to the empennage, but torquing the bolts on the Lower Fwd Angle that hold the empennage to the fuselage should remove it.

The aft fuselage C-Channel had to be widened slightly with seamers to accommodate the doubler. It's a tight spot, and all the pop rivet tails don't help!

A John Schmidt helped me to some free "AN" nylocs to use when reassembling the tail. After getting most of the bolts in, we stripped out one of the free nylocs while torquing it to spec ... not good. We removed it and discovered that it, and all the other free nylocs, were non-magnetic (unlike all the other nylocs I had in my little hardware stash). This cast doubt on the whole lot of free nylocs. Fortunately, John Koser was around and let us into his hardware cabinet where we found good nuts. Thanks John! Keith and I took out all the bad hardware and started over.

John Koser also gave us some bolts. Keith and I discovered that some Sonex-specified bolts were too long and were shanking-out. Keith's bolts (one dash number shorter) allowed us to avoid needing to double-washer. This is a common problem on the aircraft.

Some bolts on the left side of the doubler could not be installed with washers under their heads due to interference with the rudder. The bolts are in shear, so this won't be an issue. The only alternative would have been to move the fuselage side of the rudder hinge aft by approximately 1/8", requiring half the hinge to be remade.

It was a really hot, sweaty day with lots of fiddly work. Keith and I did not want to cut an inspection panel in the aircraft if we didn't absolutely have to. We fed all the hardware down into the tight space of the aft fuselage with magnets and torqued things with wrenches taped to extensions as sweat dripped from our foreheads. With the job about halfway done, we decided to quit for the day.

Wednesday 28 August 2013

Trip #2 - 2

After speaking with Dick yesterday, I decided that it would be best for him to do the engine work for me. So, I picked up the engine from Further Performance and dropped it off at Dick's shop/home in Wayzata. Dick and I discussed options for the engine. Keith had said yesterday that he felt his Sonex didn't have enough power with the stock AeroVee. I decided to go hog wild. Dick was charged with performing the following work:
  1. Install the Great Plains Force One Hub and Main Bearing.
  2. Increase displacement from 2180cc to 2332cc. This will require a new crankshaft, connecting rods, pistons, cylinders (Dick has a set of new Nikasil cylinders in the shop - very light), case clearancing, align-boring ... like I said, hog wild.
I asked Dick to keep the compression ratio low to avoid detonation, since I want to run MOGAS. AeroConversions recommends 7.0:1 for MOGAS. Dick said that 8.0:1 wouldn't be an issue on MOGAS, provided the ignition is timed correctly. Timing on the AeroVee is fixed at 28 degrees BTDC. Dick runs MOGAS at 30 degrees and 8.0:1(?) on the redrive-equipped 2332cc VW in his 601. According to him, street engines run at 32 degrees. I hope he's right! Just to be safe, I asked him to keep the compression ratio below 8.0:1, knowing that it would rob some power. I left Dick with a $900 USD deposit.

By the time I arrived at the Airlake Airport, the morning was gone. Keith has been back to the hangar and had finished removing W0014's empennage with the help of his brother, Bruce. Keith had also manufactured the doubler bars needed for the forward spar carry-through reinforcement required by WIX-SB-001. Since all aircraft are slightly different, Sonex supplies 7/8" aluminum bar stock and expects owner/builders to make this part. Thanks to Keith and Bruce! It was quite a surprise to arrive at the hangar and find these tasks done!

WIX-SB-001 Doubler Bar
The battery was totally flat. I hooked it up to a charger and it got quite hot - not taking a charge! I'm not surprised since it has sat for so long. It's time to replace it. There are lightweight lithium options now - I'll have to investigate ...

I drained all the old fuel from the fuel tank and put it in my rental car to burn. I left the tank open to ventilate. The cockpit smells strongly of fuel: I will need to fix the fuel seep at the tank sump. For those not familiar, the Sonex plastic tanks are notorious for leaking at the moulded-in fittings. Over-torque them once (and it doesn't take much) and you're screwed. To fix this problem, Sonex supplies Oops Fittings. They are an elegant solution, but would be a pain in the butt to install while the tank is in the airplane. For now, I plan to apply some sealant (Van's ProSeal replacement) to the exterior of the sump and hope for the best. It's not the nicest fix, but the sealant worked for Mervin in C-FMNX.

Tuesday 27 August 2013

Trip #2 - 1

After an uneventful flight to Minneapolis, and a great first night (and Italian dinner) with John Schmidt, it was time to get to work.

I started by inventorying the odds and ends that Joel had left in a box in the hangar to find all the hardware and parts that I would need for WIX-SB-001. As I was working on this, Keith arrived. Keith and I (together with some help from Mike Skinner) disconnected my Aerovee 2002 engine and placed it in my rental car. We left the accessory case on the airframe.

Keith and I then began removing the empennage of W0014 to allow us to do the modifications necessary to comply with WIX-SB-001. Fortunately, I found that all the necessary hardware and parts necessary were in Joel's boxes.

I should mention that it was hellishly hot in Minneapolis at this time. Keith and I could only work for a few hours before we were worn out. When we quit, we had most, but not all, of the bolts removed that hold the empennage on the fuselage. There are lots of bolts, and had resolved to not cut an access panel in the fuselage. It was slow work with a lot of reaching using improvised wrench extensions and magnets. We left the hangar to have a Coke at the FBO, and talked about Keith's impressions of the Aerovee.

Regarding the engine: After my discussion with Keith, I decided to have the Great Plains Force One Prop Hub and Main Bearing installed in my engine. Given the history of crank failures on VW-derivatives with shrink-fit hubs, it seemed like a prudent thing to do, particularly because I intend to fly aerobatics occasionally. We also talked about removing the oil restrictor plug to the #1 bearing, the subject of an optional AeroConversions SB (ACV-SB-081409). I left the airport with my engine and a list of things that I wanted Further Performance either have a look at, or do.

Great Plains Force One Prop Hub and Main Bearing
Arriving at Further Performance, I unloaded the engine and talked to Tristan. It became immediately apparent that the work I had in mind was pretty aircraft-specific and way different than what they normally do to a street engine. Tristan suggested that I talk to Dick Burns, a machinist who does the bulk of their engine building for them. I left the engine with Tristan and departed for home (John's place) with Dick's number.

My phone call with Dick was enlightening. Dick has been racing behind VW engines since the 60's and flying behind them since the 90's in a Zodiac 601HDS that he built from plans. He has built many VW aircraft engines and said that it would be no problem for him to do the machining necessary to adapt my case to the Force One Hub.

Thursday 15 August 2013

Preparing for Trip #2

Meeting Kim Johnson on Trip #1 proved to be very fortunate. Kim put me in touch with, or helped me get in touch with, two great guys: John Schmidt and Keith Rhode.

John Schmidt is your classic airplane nut - which makes him great company for an airplane nut like myself. He's working on an RV-6, has a share in a Piper Cub, flies a Stinson L-5 for the Commemorative Air Force, is nuts about Young Eagles, and I'm sure there is lots more ... what more do I need to say? This: he's a great guy too! John offered his services to help me complete the 40 hours of test flying on W0014 and the subsequent flying to get it up to 100 hrs. As a experienced taildragger driver, I was compelled to accept. He also offered his home as a place for me to stay while in Minneapolis, for which I will be forever grateful.

Keith is a retired A&P, who is the owner/builder/pilot of a kit-built Sonex. Originally powered by an Aerovee, Keith felt his airplane was underpowered and swapped in a Jabiru 3300. His expertise as a mechanic is invaluable and serves to temper my ignorance.

In fact, during my first conversation with Keith, he pointed out that Sonex had issued a service bulletin (SB) related to the Waiex tail - D'OH! Rookie mistake: check for service bulletins before you buy! Keith was correct, Sonex had issued a service bulletin (WIX-SB-001) which applied to W0014. This service bulletin resulted from the in-flight breakup of another Waiex (N75654) on October 22nd, 2011. For more information on this accident, see the NTSB's docket. The accident resulted in a fatality, and opinions on message boards and forums have been divided. I'll leave it to the reader to review the NTSB's file and come to their own conclusions.

NTSB Accident ID ERA12FA018
I did a bit more research on the SB and inquired with Joel Fuller as to whether the SB had been actioned (since W0014 had been sitting for a while, I suspected that it hadn't), and whether or not Joel had the relevant parts and documents from Sonex. The modifications required by the SB had not been completed, but Joel had the parts. I felt like a bit of a bonehead.

WIX-SB-001
This set the tone for trip #2: 1) Complete the tail SB, 2) get the engine sorted out.

My plan for the engine was to take it to an automotive shop that works on air-cooled VWs. Through Joel Herman of the Red River VW Club (I got no response from the Twin Cities VW Club), I was put in touch with Tristan at Further Performance in Minneapolis. Tristan said that his shop would be happy to work on my engine to rectify the oil leak and verify that it was assembled correctly.

I now had a plan: fly to Minneapolis, stay with John, remove the engine, take it to Tristan, and work on the tail with Keith. At the conclusion of Trip #2, I hoped to have the tail SB done, the engine reinstalled, and the aircraft ready for flight. As it turns out, that was a bit of an ambitious plan...

Wednesday 17 July 2013

The Inspection

On the morning of Saturday, July 15th, I departed for Winnipeg. Mervin and I were not planning to depart for Minneapolis until Sunday morning, so arriving in Winnipeg I found myself with some time to kill. For an aviation enthusiast, and a glider pilot, there is no better place to go for a visit than the local gliderport. Off to the Winnipeg Gliding Club I went! I met some great people and stayed for supper, some great conversation, and some great pie.

On Sunday, I drove to meet Mervin at his home in Kleefeld. I parked the rental car in his driveway and we took his wife's car and departed for Minneapolis (we didn't want to encounter a border hassle with the rental, and Merv's wife was extremely generous to grant us the use of her fuel efficient Corolla). Approximately 7 hours later we found ourselves at the Airlake airport, south of Minneapolis.

Mervin had been to Airlake previously while he was building his Sonex. There are a few Sonex aircraft that are based at this airport, and I made an attempt to contact as many owners as I could. John Koser, owner of a Jabiru 2200 Sonex (N167JK), came to the airport to meet us. Joel Fuller was also there when we arrived and he had the hangar open and N14YX pulled out of the corner and ready for inspection.

Now is the time to admit that I was not as thorough with my inspection as I could have been. Here are the principal deficiencies noted with N14YX during the first inspection:
  1. Oil leak from engine at crankcase parting line
  2. Fuel seep at fuel tank sump
  3. A few minor, easily corrected interferences on the airframe (rudder pedals, Y-rudder fairing)
That I missed things on the inspection, as will become apparent as you read future posts, actually wasn't that consequential at this time. Joel had had enough interest in the aircraft that there was no room to negotiate - this was pretty clear. As I had said in a previous post, I figured that I could sell the airplane at any time and not take a huge loss if it looked like things were starting to get out of hand or over my head.

It was time to come to a decision: take it or leave it. Based on the fact that I am writing a Blog, it should be clear that I decided to take it! Joel and I wrote up an Offer to Purchase and I handed over $4800.00 US to leave him with a large deposit of $5000.00 USD. The Offer to Purchase was drafted based on an agreement from the COPA Guide to Buying an Airplane (pp.110-111), viewable online for free by COPA members (recommended read for any Canadian contemplating an aircraft purchase).

Joel threw in pretty much everything he had kicking around the hangar, including a few tools (battery charger, power buffer), an AVMAP EKP-IV GPS, and a LightSPEED in-ear headset. I am glad for the headset ... headroom is limited for me in the Waiex.

Another person also came to meet us at the Airlake airport: Kim Johnson, president of EAA Chapter 25. Kim is a very friendly, helpful person. I reached out to Kim to gain access to his network of local pilots/mechanics. I knew that to pull this project off, and stay within my budget, I was going to have to find a local pilot to fly the flight test hours for me and that I was going to need some help. I consider myself handy, but I don't have much experience working on aircraft. I hoped that Kim could connect me with the right people.

With the deal done, Merv, Kim, and I had dinner at a Mexican restaurant in Lakeville, MN. After dinner, Merv and I then started our drive back to Canada. Once on the other side of Minneapolis, excited but exhausted, we spent the night at a hotel and finished the drive the following day.

Upon arriving in Canada on Monday, Merv and I went out to the Steinbach airport to take a look at his airplane. It really is nice - he did a great job building it. I took some photos of things that I would like to do to my aircraft.

Fuel Shutoff linkage:


Fuel shutoff linkage (and fuel seep repair):


Cabin heat diverter valve:


Cabin heat diverter valve (inside) - simple and no cable to run through the firewall:


Cabin heat box and firewall grommets:


Tailwheel linkage with rod ends (the stock Sonex linkage will ovalize the holes in the horns prematurely):


Merv also took me flying! I'm glad that I liked the way the Sonex flew .... because I had already bought one! My only complaint would be that I found the rudder to be too light. It took more work than it should to coordinate turns because I was over-controlling the rudder. Stiffer springs would help. The Waiex may not have this "problem." The "problem" could also be with me - I'm used to flying the CC-115.

After the short flight, it was off to the Winnipeg airport for me, for my return flight to Comox. What a whirlwind trip!

Thursday 11 July 2013

Ducks in a Row

Ok. Breathe. Time to start planning.

I've seen a Waiex before, but can I actually evaluate one? Doubtful. I need someone with some experience in my corner. I need to talk to a builder.

First stop: Canadian Civil Aircraft Register. There are 32 Sonex aircraft on the Canadian Registry. Not one Waiex.

Next stop: Sonex Find-a-Builder Database. 4 Waiex aircraft under construction in Canada.

What's the nearest Canadian city to Minneapolis? Winnipeg. Are there any Sonex aircraft in the Winnipeg area? Yes: C-FMNX owned and built by Mervin Friesen of Kleefeld, MB ... and the Sonex Find-a-Builder database contains his email address. Let's send him an email.

Merv replied quickly with a short note, his phone number, and a photo of his plans-built, Jabiru 2200 powered Sonex.


His airplane is as pretty in person as it is in the photo. The man is a true craftsman. He is also a true gentleman. I called him up to discuss my situation. He had been to the Airlake airport to meet with other Sonex owner-builders previously, though he had not met Joel. After a few minutes of chatting, I decided to ask him a big question: would he be interested in going to take a look at N14YX with me? He said "yes" and I proceeded to book a flight to Winnipeg.

Wednesday 10 July 2013

Hello Airplane, Buh-Bye Money

Wow! That happened fast! I was shopping for a glider, but I put a deposit on a Sonex Waiex?!?

The story, from the beginning:

I look at airplane classifieds a lot - I am generally looking at the Barnstormers Experimental listings at least once a day (it's a bit of an obsession). Every once and a while I see a deal, but I am generally not compelled to act. In the case of N14YX, I was.

I have been following Sonex Aircraft for quite some time. I like the simplicity of their designs and that they deliver a fair bit of performance per dollar (both up front, and per hour of flight). At Oshkosh in 2010, I had the opportunity to sit in a few Sonex cockpits, talk to the Monnetts and other factory reps, and take a tour of the factory. I saw nothing that gave me a bad feeling. John Monnett can seem stubborn and tough-headed when you talk to him, but he has his ideas of what is right and sticks to them. I admire that, though I may not always agree.

As a glider pilot, the Xenos had my eye from the beginning as an economical touring motorglider. Unfortunately, out of the Sonex line, the Xenos is the least common and they do not come up for sale often. Given that I am in the military and move every few years, I was not interested in building myself because I did not want to face having to move an unfinished project with the next posting or two. 

I saw the ad for N14YX early in the morning (at 05:30 on July 9th) as I was having breakfast before heading to work for an overnight trip to Sandspit, BC. She was well equipped and at $15,000 USD looked too good to be true. I called the seller, Joel Fuller, immediately and left a message. During the bike ride to work I got to thinking ...

Pros:
  • Priced at less than the price of a Waiex Complete Airframe Kit ($15,995 USD at the time of writing) alone ... not to mention engine, instruments, avionics, paint, hardware, and handy upgrades to the basic kit from Sonex (pre-assembled spars, machined angle component kit)
  • Well equipped for day VFR
    • Dynon EFIS-D10A and EMS-D10 digital instrumentation
    • XCOM radio
    • Microair Transponder
    • 406 MHz ELT
Cons:
  • Location: KLVN, Airlake Airport (Lakeville, Minnesota - south of Minneapolis)
  • Unproven: the aircraft has flown only 10 hours
  • Aircraft has been sitting for six years
  • Phase 1 flight testing (40 hrs) not complete
Misc:
  • AeroVee engine
Photos from the ad on Barnstormers:




  
The getting the aircraft home to Canada was certainly going to have its challenges, but I figured that, given the price, at any point in the process I could sell the airplane and not get totally hosed.

Joel called me back as I was flight planning at work at approximately 07:30. We had a brief conversation and I knew that he was about to be flooded with calls and emails so I asked him if he would take a small deposit to hold the aircraft so I could arrange to go see it. He agreed and I told him I would contact him that evening and send him a deposit via PayPal.

Once settled into the hotel at the end of the day, I gave Joel a call to send him some money. He informed me that another fellow, local to Minneapolis, had called. Joel decided to let this fellow (let's call him Buyer #1) take a look at the airplane first. Reasonable, yes, but I was pretty disappointed. I was kicking myself and thinking that I should have sent a token deposit immediately after getting off the phone with Joel.

Upon returning from Sandspit the following day (July 10th), I checked my email. It had news from Joel: he showed the aircraft to Buyer #1 and Buyer #1 decided that he wasn't ready to buy. Was I? Willing to gamble $200 USD (as a non-refunable deposit for Joel) and the cost of an airline ticket, I guess I was.

The adventure begins ...