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Forward Fuselage

Time-lapse Video, 900 hours of work and move to airport.

This video includes all the time-lapse footage I have from January 2014 until August 2015. It’s essentially the entire build of the airframe. It’s missing the first 200 hours of the project because I didn’t have the camera setup for that portion of the build.

Categories: Aft Fuselage, Delivery and Workshop, Electrical, Fuel, Misc, Empennage, Engine Cowling, Firewall Forward, Flaps and Ailerons, Forward Fuselage, Fuselage, Fuselage Completion, Hangar Completion, Main Wings, Turbo Aerovee Engine, Videos, Waiex #197, Wing Spars, Wings | Leave a comment

Forward Fuselage #10 (Engine Mount)

Total Build Time: 666 Hours. The engine mount was included in the kit from Sonex and was pre-welded to specs. Fitting the engine mount for the first time was a bit nerve-wracking, since it depended on all of my measurements in my assembly of the front fuselage to be accurate.   Since my Waiex will be … Continue reading »

Categories: Forward Fuselage, Waiex #197 | Leave a comment

Forward Fuselage #9 (Seat Installation)

Total Build Time: 661 Hours. Finally, the seat installation… a fabrication and assembly process that I’ve both been dreading and looking forward to, for quite some time. Dreading because it involves large accurate bends in aluminum sheet metal that I have not performed before (and is typically done on a proper bending brake, which I … Continue reading »

Categories: Forward Fuselage, Waiex #197 | 3 Comments

Forward Fuselage #8 (Flap detent, elevator push-rod cover)

Total build time:  646 Hours.   Two more small details in the cockpit before I get to completing the seat installation. First is installing a protective cover for the elevator pushrod that eventually will go from the control sticks, down the center of the bottom of the seat, back to the idler bellcrank. A few cuts in the pre-bent cover … Continue reading »

Categories: Forward Fuselage, Waiex #197 | 3 Comments

Forward Fuselage #7 (Glare-shield and Instrument Panel)

Total Build Time: 640 Hours. The glare-shield is essentially the dashboard of the aircraft… it lies behind/above the instrument panel and connects the area between the instrument panel and the firewall.  It’s somewhat ironic that it’s called a glare-shield in my aircraft, since the usual purpose of a glare-shield is to reduce the glare from … Continue reading »

Categories: Forward Fuselage, Waiex #197 | 2 Comments

Forward Fuselage #6 (Aft lower cabin details, idler.)

Total Build Time: 634 Hours. There are quite a few details on the floor of the forward fuselage, under the area that will eventually be the seat. I made a few angle components, including one that will support the lower part of the seat sling. A clearance is cut in the angle to allow the … Continue reading »

Categories: Forward Fuselage, Waiex #197 | 1 Comment

Forward Fuselage #5 (Fuselage Box assembly, floor, and spar tunnel.)

Total Build Time: 612 Hours. With the side panels complete, it’s time to start putting the forward fuselage together! I positioned the aft fuselage and flipped it upside down.     I shimmed the fuselage and placed a table to support the side panels. I taped some 2×2 wood to the upper longerons to protect … Continue reading »

Categories: Forward Fuselage, Waiex #197 | Leave a comment

Forward Fuselage #4 (Side panel Riveting, NACA vents, upper longeron slots, polishing)

Total Build Time: 584 Hours. At this stage in the project, I made a couple decisions that would further modify my Waiex from the plans. One decision was to add some large vents to the side panels to provide extra ventilation in the cockpit. After reviewing pictures and consulting some other builders, I found what … Continue reading »

Categories: Forward Fuselage, Waiex #197 | 1 Comment

Forward Fuselage #3 (Upper and Lower firewall)

Total Build Time: 576 Hours The firewall is literally a wall of steel near the front of the aircraft that separates the cockpit from the engine compartment. It serves to contain the heat of the engine from the cockpit, as well as a safety barrier in case of a fire in the engine compartment. The … Continue reading »

Categories: Forward Fuselage, Waiex #197 | Leave a comment

Forward Fuselage #2 (Side panel assembly)

Total Build Time: 556 Hours My angle component fabrication is complete for the forward fuselage side panels, so now comes the task of aligning the parts into the proper positions on the side panel skins.   For fun, I put the skin into its position relative to the aft fuselage, to get an idea of … Continue reading »

Categories: Forward Fuselage, Waiex #197 | Leave a comment

Forward Fuselage #1 (Angle material fabrication)

  Total build time: 546 hours. My wings, aft fuselage, and empennage are complete. Work now turns to the forward fuselage, which ties everything together. The wings, aft fuselage, engine and pilot are all connected through the forward fuselage. This means that the forward fuselage is both complex and very strong. Strength comes largely from … Continue reading »

Categories: Forward Fuselage, Waiex #197 | 3 Comments