Tailbeacon on a Waiex
Posted: Sat Mar 30, 2024 9:18 pm
by Bryan Cotton
So we got tired of waiting for the Echo UAT story to unfold, and bought a tailbeacon. The only problem is we didn’t put a tail nav light in the Waiex. Well, we are now.
First problem is wire routing. For the right tail, I put holes down the row of ribs to run the pitot tubing. I installed the tip on both sides with nutplates, but did not put holes in the ribs on the left side.
The tail forward of the spar has only two ribs. The one at the tip, and the one down near the fuselage. The bottom hole is forward of the little bulkhead between the Y tails. Just need a 4’ 1/4" drill bit to transfer the two holes to the fuselage. I beveled the edges of a 1/4" rod and a 1/4" drill bit, jigged them up, and welded them together.
Screenshot_20240330-162001-434.png (635.37 KiB) Viewed 10874 times
Next I ground down the weld.
Screenshot_20240330-162118-390.png (769.02 KiB) Viewed 10874 times
Ran the hole through the fuselage.
Screenshot_20240330-164948-508.png (643.1 KiB) Viewed 10874 times
I’m currently pulling some 1/4" OD tubing through the holes. To be continued…
Re: Tailbeacon on a Waiex
Posted: Sun Mar 31, 2024 1:29 am
by Bryan Cotton
Conduit runs
conduit in the back.png (558.71 KiB) Viewed 10848 times
conduit by the mixer.png (611.54 KiB) Viewed 10848 times
conduit baggage area.png (659.8 KiB) Viewed 10848 times
Re: Tailbeacon on a Waiex
Posted: Tue Apr 02, 2024 8:58 pm
by MichaelFarley56
Nice pics Bryan,
I was seriously considering a Tailbeacon X and the AV-20 but was also struggling with where to install the tailbeacon. I was about to modify the rudder and make a new upper cap when I decided to go a different route. I also tried the AV-20 in my panel but it doesn’t like the stock panel tilt so I returned it. Too bad I liked the idea of another artificial horizon!
Good luck on your install. I ended up buying a Sandia STX-165R (controlled by the MGL Xtreme) and an Echo UAT which works well so far
Re: Tailbeacon on a Waiex
Posted: Tue Apr 02, 2024 9:24 pm
by Bryan Cotton
Mike,
I really wanted an EchoUAT but I waited too long.
Re: Tailbeacon on a Waiex
Posted: Wed Apr 10, 2024 10:53 pm
by Bryan Cotton
One of the challenges we face is that the lock ring that holds the tailbeacon in place is designed for a vertical trailing edge. The Waiex trailing edges of the tips are not vertical. We were going to use the supplied aluminum lock ring and fair it into the tail, but having the mounting screws vertical were making for an ugly interface for the fairing. So, Adam has scanned/redesigned the lock ring to reclock the tabs. Here is the original aluminum part compared to a 3D printed part:
aluminum vs plastic lock ring.png (472.24 KiB) Viewed 10399 times
We are not going to use the 3D printed part, but will CNC out a part from a piece of 1/4" HDPE sheet. This shows how the redesigned part holds the tailbeacon vertical but has the mounting screws aligned with the trailing edge.
re-clocked lock ring.png (425.58 KiB) Viewed 10399 times
Re: Tailbeacon on a Waiex
Posted: Thu Apr 11, 2024 7:59 pm
by Bryan Cotton
I’m curious if other Waiex builders see this as a good ADSB option or not. Should we tool up to make one or a run of them?
Re: Tailbeacon on a Waiex
Posted: Fri Apr 12, 2024 1:28 pm
by alphapapafoxtrot
Is Waiex middle small rudder too small for tailbeacon?
Re: Tailbeacon on a Waiex
Posted: Fri Apr 12, 2024 1:38 pm
by MichaelFarley56
alphapapafoxtrot wrote:Is Waiex middle small rudder too small for tailbeacon?
Good question and one I was thinking about as well. Originally I was thinking about a Tailbeacon X as well for simplicity and was contemplating a redesigned upper rudder cap that could keep the Tailbeacon X in a vertical position, with the possible added bonus of increasing the rudder surface area to provide more low speed directional control (i.e., during landing). I ultimately went another route but my three concerns with this setup was, 1. Figuring out how to run wiring to a moving control surface, 2. The added weight put on the rudder hinge, and 3. Drilling a hole in the aft Y tail spar assembly.
I’m guessing the rudder itself would be fine with a few extra ounces on top, but that would be subjecting the rudder hinge to additional forces, and I have no idea that’s acceptable or not.
Ultimately I think Bryan’s idea of running a tube up the leading edge of a stabilator and mounting the Tailbeacon X on a tail tip would be the safest and simplest solution.
My two cents of course…
Re: Tailbeacon on a Waiex
Posted: Fri Apr 12, 2024 1:57 pm
by Bryan Cotton
alphapapafoxtrot wrote:Is Waiex middle small rudder too small for tailbeacon?
I don’t think it is too small. But I skipped the mini-rudder for 2 reasons:
- You have to get wires across the moving rudder to the non-moving fuselage. Can be done, lots of antique Cessnas etc with this setup.
- Adding weight on the trailing edge will make flutter characteristics worse. Probably not an issue, but definitely not desirable.
The worse thing about my solution is that it is not symmetric. I think it will look ok though.
Re: Tailbeacon on a Waiex
Posted: Tue Apr 23, 2024 9:58 am
by Bryan Cotton
Adam has made a couple of lock rings out of HDPE on the CNC router. It took him a couple of tries to get the tool path right. He also made a 3D printed tool for drilling the holes for the 2 screws that prevent the beacon from unlocking itself in flight.
That also took a couple of tries to get right. The shape is milled out, with the locking tabs full thickness. Then the part goes in the 3D printed tool, and we use the drill press to drill through the part and all the way through the tabs. Those holes are tapped for an M2 screw, then the tabs are milled to their final shape. It leaves a half hole in the tab, which matches up with a half hole in the beacon tab.
We have some 3/16" 6061-T6 on the way to make an aluminum part, like the one supplied with the tailbeacon but clocked for the Waiex.
Meanwhile I’m working the electrical side of the project. I soldered on a Deans 3-pin connector onto my wire.
Deans 3 pin connector.png (883.08 KiB) Viewed 9683 times
A little WD40 and some determination and I was able to push the wire through my conduit. For now I have just chucked a loose piece of shrink wrap over the connector for safety and tie wrapped it in place. The compression fitting originally had a pipe thread on one end. I hacked that off, drilled the hole inside for the tube to pass through, and am using it as a stop so the tube won’t get pulled into the tail.
Next up is the fun part - terminating that wire under the panel somewhere. When this is done, I’ll be able to remove the tail tip with the tailbeacon on it, and then remove the tailbeacon from the tail tip.
Re: Tailbeacon on a Waiex
Posted: Sat Apr 27, 2024 12:45 am
by Bryan Cotton
The perils of working behind the panel on a Sonex. Nearly impossible to add a wire. I haven’t succeeded yet but still trying.
Adam has made the first aluminum lock ring. Needs work but looks really promising.
Re: Tailbeacon on a Waiex
Posted: Sat Apr 27, 2024 12:00 pm
by Bryan Cotton
News flash: my wire is terminated. Now I just have to hook the 167 things back up that were in the way.
Re: Tailbeacon on a Waiex
Posted: Sat Apr 27, 2024 8:00 pm
by WaiexB22
Looks great! I would love to see some overall pictures with it when you’re done.
Re: Tailbeacon on a Waiex
Posted: Sat Apr 27, 2024 8:48 pm
by BobDz
Bryan Cotton wrote:News flash: my wire is terminated. Now I just have to hook the 167 things back up that were in the way.
I DEFINITELY need new glasses!!!
I thought your wife was terminated.
Re: Tailbeacon on a Waiex
Posted: Sun Apr 28, 2024 10:05 am
by Bryan Cotton
Robert, I’ll definitely post pictures. We are getting close. Adam may have a good lock ring today and then will work on a mold for the tailbeacon mount/fairing. We plan to make a conical-ish 3D printed male mold, lay up glass on the outside, remove the plastic, slice the tail tip and bond it in.
Bob, though I did not write what you thought you saw, it’s backwards WRT who terminates and who gets terminated.
I got about 152 things put back. Smoke test successful. While I had the convenience of the seat, baggage area, and stick out I replaced the right brake line. It had failed near the wheel due to rubbing on the gear leg fairing and I did a temporary splice fix a few weeks ago.
Re: Tailbeacon on a Waiex
Posted: Sun Apr 28, 2024 11:34 am
by WaiexB22
152 is better than 167..keep up the progress.
Re: Tailbeacon on a Waiex
Posted: Sun Apr 28, 2024 11:42 am
by Bryan Cotton
WaiexB22 wrote:152 is better than 167..keep up the progress.
167-152=15 things to go.
Re: Tailbeacon on a Waiex
Posted: Sun Apr 28, 2024 1:06 pm
by flyguy0609
BobDz wrote:
Bryan Cotton wrote:News flash: my wire is terminated. Now I just have to hook the 167 things back up that were in the way.
I DEFINITELY need new glasses!!!
I thought your wife was terminated.
Same here, Nice to know I’m not alone.
Re: Tailbeacon on a Waiex
Posted: Sun Apr 28, 2024 9:10 pm
by Bryan Cotton
Re: Tailbeacon on a Waiex
Posted: Thu May 09, 2024 10:02 am
by Bryan Cotton
Next up we need the fairing/mount in the tail. We have printed a male mold. The fairing will sort of be a cone shape, but stretched along the trailing edge where the screw holes are. After we make the cone, we will hack up the tip and bond it in.
Re: Tailbeacon on a Waiex
Posted: Sun May 12, 2024 11:28 am
by Bryan Cotton
Initial layup for the tailbeacon fairing. I wet sanded the 3D printed mold until it was smooth. Then I painted it, sanded some more, and covered it with thin plastic packing tape. I waxed the tape for release and laid up one ply to start.
Re: Tailbeacon on a Waiex
Posted: Sun May 12, 2024 6:58 pm
by Bryan Cotton
Here it is removed. Only one ply so not very stiff.
I removed the bottom rib. Mostly sanded off the rivet heads and then drilled.
Here is my hack job. Came out terrible.
With the male mold inside, I’m gluing the cone in with 5 minute epoxy.
Next up: sanding, wet layups, and so on.
Re: Tailbeacon on a Waiex
Posted: Mon May 13, 2024 10:05 pm
by Bryan Cotton
I’m laying up cone #2. Q/A didn’t like the alignment so I ripped it out and doing it over. I’d take a picture but it looks exactly like the first cone layup picture.
Re: Tailbeacon on a Waiex
Posted: Tue May 14, 2024 2:18 pm
by Bryan Cotton
Try #2. This one is not totally by eye. We figured out a good reference as shown.
Here is the flat pattern for the physical mount. I’ll have a couple of 1-leg #8 nutplates installed. The 4 tabs will bend back 90 degrees and rivet to the fiberglass. The long tab will have a wire attached to it, probably with a lug, screw, and nut. This will let me ground the mount as shown in the tailbeacon installation manual.
flat pattern tail light mount.png (771.57 KiB) Viewed 4679 times
Re: Tailbeacon on a Waiex
Posted: Thu May 16, 2024 1:29 pm
by Bryan Cotton
Re: Tailbeacon on a Waiex
Posted: Tue May 21, 2024 10:38 am
by Bryan Cotton
I didn’t finish before the weekend, so did a little speed tape and a quick flight test to 120kts.
Here was my first attempt at bending up the aft mount.
Screenshot_20240516-222323~2.png (416.61 KiB) Viewed 4239 times
I could not get the bends tight enough to work, so I aborted the outside tabs idea and riveted tabs on the inside.
Re: Tailbeacon on a Waiex
Posted: Wed May 22, 2024 8:00 pm
by Bryan Cotton
Note this lock ring is on backwards. I’m just using it for stiffness. This part was too loose to use.
Screenshot_20240522-175719~2.png (408.74 KiB) Viewed 4154 times
The tabs are bent up nicely and I can see them with the flashlight trick. After it is riveted on I’ll do a couple more plies, to both close up the end and hide the flush avex aluminum pops that aren’t there yet.
Next up: drill and rivet. I think I’ll get the tailbeacon on before I finish the bodywork and paint. That has sort of become my style. Still need to finish that on the fresh air inlet as well.
Re: Tailbeacon on a Waiex
Posted: Thu May 23, 2024 11:23 pm
by Bryan Cotton
My sheetmetal piece is a bust. The mounting tabs are interfering with the skybeacon. Not enough room. Anybody doing something similar, I recommend making it bigger. What I am going to do to recover is make a laminate of glass, 0.025" aluminum, glass, and bond it into the cone. Stay tuned.
Re: Tailbeacon on a Waiex
Posted: Thu Jun 06, 2024 9:16 pm
by Murray Parr
Bryan Cotton wrote:Adam has made a couple of lock rings out of HDPE on the CNC router.
What CNC Router do you use? Does it also do aluminum? I’m asking because I haven’t fed my tool fetish for a while…
Re: Tailbeacon on a Waiex
Posted: Thu Jun 06, 2024 10:54 pm
by Bryan Cotton
It’s a Probotix Fireball V90. Found it on the local classifieds for about $300.
It is not awesome for aluminum. Too flexible.
Re: Tailbeacon on a Waiex
Posted: Tue Jun 25, 2024 2:43 pm
by Bryan Cotton
Rev 2 of the mount:
Screenshot_20240623-230719.png (956.75 KiB) Viewed 2328 times
Rev 2 may not be totally accurate. But next I glued it on with 5 minute epoxy. Once it seemed strong enough I did a trial fit.
beacon trial fit.png (931.05 KiB) Viewed 2328 times
I cut the heads off some long #8 screws and sharpened them. Then I screwed them in, with some WD40 on the threads. Put a piece of heat shrink tubing over it and then glassed over with 4 or 5 layers of thin glass. Before I put resin to it, I cut up to the edge of the mount around the perimiter of the part so the cloth would lay flat around the corner.
Re: Tailbeacon on a Waiex
Posted: Sat Jun 29, 2024 8:46 pm
by Bryan Cotton
Ready for paint - finally.
Before paint I weighed it, + 0.06 lbs so far.
Re: Tailbeacon on a Waiex
Posted: Sun Jun 30, 2024 10:50 am
by Bryan Cotton
Here is my wiring scheme:
I need to touch up the paint. Good enough for now.
Powered up, configured, and registered:
tailbeacon powered up.png (936.53 KiB) Viewed 2014 times
Awesome! Weather is spectacular, let’s go try it out!
Oh wait…
Re: Tailbeacon on a Waiex
Posted: Fri Aug 02, 2024 1:21 pm
by Sonex1717
Those tail beacon pics turned out great Bryan! Van’s used to carry something like yours but haven’t in years. If possible please let me know if I can purchase one from you. Unfortunately I have no skills when it comes to molds & machining lock rings.
Don
Re: Tailbeacon on a Waiex
Posted: Fri Aug 02, 2024 2:52 pm
by Bryan Cotton
Sonex1717 wrote:Those tail beacon pics turned out great Bryan! Van’s used to carry something like yours but haven’t in years. If possible please let me know if I can purchase one from you. Unfortunately I have no skills when it comes to molds & machining lock rings.
Don
Thanks Don! We don’t have the bandwidth to make parts unfortunately. Are you any good at fiberglass? We can share the 3D model we used to make the cone. If you have a straight tail Sonex you won’t have to machine a lock ring for an Uavionix tailbeacon. The one they supply will work.
Re: Tailbeacon on a Waiex
Posted: Sat Aug 03, 2024 1:07 pm
by Sonex1717
Yes I have the straight-tail but unfortunately no glass experience. It is hard to believe that no one on the planet is making an after-market flared mount! Thank you for your kind offer to share the 3D. Do you prefer the Uavionix over the AeroLED?
D
Re: Tailbeacon on a Waiex
Posted: Sat Aug 03, 2024 2:51 pm
by Bryan Cotton
Sonex1717 wrote:Do you prefer the Uavionix over the AeroLED?
Two totally different things. Uavionix provides ADSB out. Plus it’s a tail light. I have Whelen Orion 600s on the wingtips so I don’t need a tail light, but I do want ADSB out.
Re: Tailbeacon on a Waiex
Posted: Sun Aug 04, 2024 4:20 pm
by Sonex1717
Thanks again for the info Bryan. I’m gathering details about lighting and radios as I go while working on the tail feathers. A lot of considerate builders like yourself have taken the time to post, and it is appreciated.