Waiex Project

[Morph]

Be careful not to use any other cleaner such as MEK, Thinners etc. Polycarbonate glass stains very easy and solvents cause it to crack immediately. Test it on an old piece of glass.

Rough up the surface slightly along the glue line with sandpaper for better adhesion

my Bushbaby door windows and side windows are glued straight on to the metal using white sikaflex "en dit sit f%^&&^n vas".

also if you do rivit remember to drill a slight oversize hole in the polycarb, i.e. 3.5mm for a 3.2mm rivit, to allow for expansion, of the glass, otherwise you get cracking.

Sikaflex is designed to glue in car and boat windows.

[RudiGreyling]

Hi Guys
<SNIP>

Unfortunately to late for me, BUUTT my second one is in and done!!!! Latch in and working, closes ok, about 95% happy with the end product, which I have to accept, being first time etc!
<SNIP>

Had long talks to caa today, am going to try to get exemption from stress testing, and go straight to flight testing. Can be difficult, but do-able. Also got a copy of a Swiss certification, and trying to get the UK one. Applying for registration now, and sending in motivation letters for exemption etc. Hold thumbs!!

Larry,

Yip my canopy is also not 100% in the looks department, but it is good and functional enough and 100% safe. At some point a home builder needs to accept it and move on, otherwise you will spend many many hours to fix that last 5% for looks, and you might never get it. It is a homebuildt, build it good and safe. It is not a production build airplane.

I hope you get CAA sorted out soon. Please try and not give in to their structural load testing requirement. If you can get documentation from kit manufacturer to support it get it and give to CAA. CAA need to wise up, if another authority approved it, then they need to accept it. If the tests was done and you build the kit according to plan without mods, then CAA need to accept it. If one person gives in to CAA then it becomes the defacto for future builders. Try and keep the faith, and fight the fight for your fellow builder that come after you.

[Morph]

if it does look unsightly through the glass, use matt black vinyl on the outside to make a frame. Alternatively Boet masks it off, then uses matt black metcoat primer (or the stuff you paint fireplaces with) and paint a frame. I prefer the vinyl because it can be removed and replaced easily. I used the off cuts from my lettering. Again if you are going to use paint, test it first on scrap glass to see if the solvents react to the glass

[RudiGreyling]

if it does look unsightly through the glass, use matt black vinyl on the outside to make a frame. Alternatively Boet masks it off, then uses matt black metcoat primer (or the stuff you paint fireplaces with) and paint a frame. I prefer the vinyl because it can be removed and replaced easily. I used the off cuts from my lettering. Again if you are going to use paint, test it first on scrap glass to see if the solvents react to the glass

Ditto, good suggestion, I painted the outside of mine, 1/8" wider than glue joint, hides it and protects it from the Sun.
My canopy has a split in the middle, the paint makes it looks like a TARGA top, but vinyl will work.

[LarryMcG]

Thanks, Rudi

Will keep you posted, and will definitely not be stress testing. Hoping to have answers soon, otherwise Klaus from CAA will be away for 3 weeks, from end next week. Not sure if I will be able to hold her down that long!!
L

[Morph]

otherwise Klaus from CAA will be away for 3 weeks, from end next week. Not sure if I will be able to hold her down that long!!L

There are others in that division that can help you. Dean Khumalo is their boss. I emailed him and suddenly things happened

KhumaloD at caa . co . za

[LarryMcG]

Wings are on, flaps, rudder and Ailerons are connected.

Ran the motor again, sounds sweet.

Needs fuel cap cover, Rudder trim tab, wing and flap fairing against fuselage, choke needs to be sorted, instruments need to be tuned - 1 egt not working, two cht wires to short, engine rpm not reading.

Should hopefully get exemption from static load testing from caa shortly. Needs final inspection, the proving flight autho from caa.

Looks like a real plane now!!

Will post pics.

LM

[AndyCAP]

Looks like a real plane now!!

Will post pics.

LM

PLease do! & good luck with CAA

[grostek]

Hi Larry,

On ABF now? (Absolutely Bloody Final)

Keep chipping away and soon you will have nothing left to do except FLY

Good luck with CAA

Kind regards,

Gunter Rostek.

[Miskiet]

I saw a Sonex at Rainbow aircraft while flying the Gauteng Champs. There are also a few Sonex's flying in SA. The structure should be the same as your plane apart from the tail section - No load testing should be necessary as CAA should already have all the info on file.

[LarryMcG]

No, no Sonex registered in SA at this stage. Only one flying - legally - as far as I know is the one at Springs, and that was built and registered in Zim, so whoever buys it will have the same hassels.

There are at least 6 more Sonex nearing completion, with one ready to Fly in Klerksdorp, another in PE, another in Bloem, one near Jhb, etc.

BUT GUESS WHATTTTTT???????? Got my Exemption through today , so plane will have final inspection on Sat, and I'll submit application for proving flight Auth next week.

End of the month should be deadline!!!

[grostek]

Congrats Larry,

The relief must be immense.

Now go and do some celebrating.

Enjoy.

Kind regards,

Gunter Rostek.

[AndyCAP]

Fantastic news Larry!! "Min dae" now!

[RudiGreyling]

Mooi Man! Pictures???

[LarryMcG]

Hertewith the promised pics.

Canopy and cowling just put in place. Spats and fairings still to be fitted, after test flying. Wing fairings need to be riveted, but trying to find a finishing solution.
Very tight connecting flap pusrods, in the wing, had to use riveting rosi's small hands.
Should finish most of the stuff this weekend, should be able to do some test taxing.

Need to check all settings of flaps, ruddervators etc. Install some upholstery.

Final Inspection booked for next Sat, then submit docs!!

VERY CLOSE