Waiex Project

[LarryMcG]

Hi All

Many thanks for the encouragement!
Have started following forums on jab engines, to rid myself of all the negative comments that one hears! Check what one guy says about this! Will certainly be visiting all over the country, once done. Climbs at 900 fpm, at 110 mph!


My Sonex has only flown for 7 hours, and so my information is not solidified yet. But the information might be of some value.

1. Prop - Sensenich 54x48 wood - I have no indication of over revving from my test pilots. But I think it will hit 3300 rpm WOT.
2. Climb rate - the test pilots have indicated a climb between 900 and 1000 feet solo at about 110 mph. (about 5 - 10 degrees C) We are not pushing the rate of climb too much because the engine is new and tends to get hot with too little speed. As the engine breaks in we will be able to lower the climb speeds and perhaps the rate of climb will change. We have not loeaded the plane to gross weight yet.
3. Altitude - My test pilots have flown up to 6000 feet to do the airwork.
4. Fuel Burn - On the first flights, which includes some slow flight and circuits, we are using about 13.5 liters per hour. That's with the Bing carb and the original jets.
5. Reliability - Only 7 hours so far but the engine is running fine. Both test pilots love the way it runs - smooth and powerful.
6. Gas - Avgas 100LL
7. Happy? - Yes, except it is light and the weight and balance tends to be closer to the rear. I'll have to be careful with heavier passengers and less than full tanks. I've received positive comments on how it sounds. I like the economy of the engine. I have the solid lifters, so I have to do the valve maintenance regularly. That's probably a good thing, because the cowls are off and you can look around the engine compartment regularly. Uses very little oil and this may even be reduced as we break in the engine more.

[Marc G]

Looks awesome Larry... Can't wait until it flies!

I'm glad to see you got Aunty Sharon helping! (or is she supervising?)

[RV4ker (RIP)]

AWESOME....

How difficult is it? I have been told most of these are like putting mechano together, but is it that simple?

It is so frustrating to see all the guys putting together these awesome kits. I am dying to try one, but I am unsure of my ability to see it through. Although I can help myself this seems like such a huge project. What is build time and what (if I may ask) is estimated final cost?

PS
Need some tips on fairer sex recruitment techniques....

[LarryMcG]

Hi RV 4ker

Before selling the jora top start building, I was extremely wary, nervous terrifed etc. I didnt want to be one of the statistics of starting and not finishing.

But, took the plunge and ordered!

Was more terrified, when the kit arrived. Didnt know where to start, what to do or how to go about it. First time for me, for anything remotely along these lines.

Got hold of an elderly aviation enthusiast, and discussed with him, and asked if he would be prepared to help. Spoke about a cost per hour, settled on a reasonable figure, and he jumped at it.

It IS a LOT of work. Lots of cutting angle pieces, making ribs, drilling holes, measuring etc. But, it is hugely rewarding, to watch it coming together, and knowing the day will arrive, that we can test fly - with or without friggin c-- permision! The biggest problem has been in understanding the plans, and what they want from us. Also, very easy to read the plan, jump to a conclusion, and miss another small detail, only to find out afterwards you got something wrong. So, the secret is to READ the plan very carefully, even with a highlighter, marking off, and then measure a few times before cutting!

We now work very well together, or apart, but the main thing is the motivation for each other. We try to start work sometime during the afternoon, or evening, and work until 7 - 9 pm. This works very well, because while I'm at work, I picture him carrying on without me, so I rush home. Same applies for him, thinking that i might be working, so we motivate each other to carry on.

Im not sure if things would have gone as well, if I was building alone. Also give you the opportuntity to discuss any problems, parts missing, not understanding the plans etc.

Predicyed time was 700 - 900 hours, and I think we might be about right, as we are on 350 hours now, and hopefully about half way, in 3.5 months. So, should be airborne by about March. Cant wait!!

Anyone welcome to visit anytime, to help, learn, or only look.

LM

[RV4ker (RIP)]

Think you got it spot on. Building alone scares me. More so from frustration and lack of debate than from any other angle. I did it with the KR and while rewarding it was K@K, frustrating and the kyk weers got a bit much. Having a critical sounding board around must make a huge difference.

Anyone know if there is a basic metalwork type class being run by anyone locally? There are some many guys offering RV builds I wonder how long before we get a builder assist program or intro build course (build the tail section here wih us in our workshp with our tools to get the hang of it type setup)... I am keen on building and RV10 with my lighties once they are a bit bigger (say 5 years time), but like me pops I assume they will no longer be interested in it when time/cash permits. I think it would be far cheaper to chuck the boodle at it and buy a flying one, but that not really the point.

Getting back to the project at hand. I would love to take a lookeesee, but given that I can't even get to Rudi just down the road I doubt it gonna happen.

As they say RIBBIT RIBBIT RIBBIT...

Enjoy it. It looks awesome...

[Boet]

Or you can fit one of these.......

[The Agent]

Whats up Larry??

[swiftprop]

Larry
What do you think about the VW engines/ What is the max horsepower you can get as an aero mod?
Best wishes
Andre

[LarryMcG]

Ok, so you all thought we had given up! Ok, so we did, for about two hectic months, at the end of last year, when business pressure got tooo bad!
But now, back into the full swing of things again, working late afternoons and evenings.

A big job has been the assembly, and solid riveting of the main spars - pics below.

Also had a very useful gt450 flyer - Straydog's been busy again! - got caught here for a few days in bad weather, so put him to good use.

Oh, and engine is here!!!! Jab 2.2.

[LarryMcG]

Andre, to be very honest, I am not a fan of any of the vw motors, which is why I decided on Jab. Had that engine out in the Raven a while ago - on Aerovee, helps prove my point!
Also decided on the 2.2 jab, hoping for better fuel economy, and range.
Time will tell!
Gary Butlion has just assembled his aerovee, in PE, for the Sonex, and should be testing in the next few weeks. Says he went for the slighly lower compression ratio, so will probably get slightly less than the advertised 80 hp.
Will be interesting to fly the two planes against each other when done. Factory says no difference between the two, so will see!


Spars finished, now busy with ribs - below!

[LarryMcG]

Cockpit coming along, firewall in, main sparbox assembly going in, and ribs being trimmed at flanges, and brackets installed.

[grostek]

Hi Larry,

Very nice riveting on the spar.

That spar looks strong enough for 12G!

As a matter of interest how strong is the spar?

Keep plugging away and soon all small jobs will be done.

Kind regards,

Gunter Rostek

[swiftprop]

Hi Larry
Thanks for the info. Looks like you are moving! :D :D Well done to the Softness for doing some manual labour, or should we say womanual labour? Please pass on the accolades, You are priveleged to have this type of support!
Best wishes
Andre

[Rudix]

Great stuff Larry, looking good !

I agree with you on the VW/Jabiru decision, I have just made the same decision for the Zodiac, even though that AeroVee is tempting I would rather have peace of mind.

Keep up the good work and thanks for sharing it with us !

BTW, that new Jabiru 2.2 looks good, but I think they sent you the cooling ducts from the 3300?

Happy building,
Fly safe,
Rudi

[LarryMcG]

Well picked up, Rudix! Accidently posted some pics that were taken in the Jab factory a while ago, of a 3.3!!!

My 2.2 IS in the garage, with the correct cowls. Those supplied by Sonex, for the engine installation, are aluminium, and THOSE are made for a 3.3, so will need cutting, if I decide to use them!

Not exactly how strong the spars are, but I know someone who jumped on them, - not mine! - while attached only at the root only, to try to straighten the bow after riveting, so they are strong! Mine dodnt bow very badly after riveting, seems the more clcos you put in, the straighter the spar after you finish. Plane rated for +6-3 G, but apparently tested to double! Cant wait for the first loop and roll!

Andre, if she wants to fly, she must help build!!!

Thanks for all the support!!


L