Dave's Sonex Builders Log

Welcome to my builders log for Sonex S/N 767. It won't be as big as a real 767 but if you scale the speed I bet it will be almost as fast.

SECTIONS
Recent Entries Only
All Entries
1. Elevator
2. Firewall Forward
3. Fuselage
4. Horizontal Stabilizer
5. Landing Gear
6. Planning and Paperwork
7. Rudder
8. Tooling
9. Vertical Stabilizer
10. Wings
Hours Summary
Construction 987.04
Planning / Misc 6.10
Tooling 17.63
TOTAL 1010.77
Printable Log
Builders Log
Canadian Builder Links
RAA
MD-RA

Canadian Aviation Regulations
and Standards
Part V - Airworthiness

Std 507 - Flight Authority
Std 549 - Amateur-Built Aircraft
Exemption to Reg 549.01

FAA Advisory Circulars

AC 43.13-1B
AC 43.13-2A
Search for Advisory Circulars
Links
Sonex Ltd.
Aero-Conversions, Inc.
Jabiru Canada

The AeroElectric Connection
Microair Avionics
Becker Avionics
XCOM Avionics

Duckworks
GS-Air

Dynon Avionics
Grand Rapids Technologies, Inc.
e-mail
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WELCOME!

This website is to log my progress while building a Sonex airplane. I purchased the plans for Sonex S/N 767 and began construction around Christmas 2004. I would like to keep my costs down and am currently considering the AeroVee engine. I'm leaning strongly towards tricycle gear.

I've finally settled on using an AeroVee engine and going with the tricycle gear. I know, everyone thinks a Sonex should be built with a tail wheel but I like the tricycle gear and I'm sticking with it.

Recent Builders Log Entries

Sep 1/14
Canopy Fittings
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-D01
1.44 hrs

Aug 30/14
Canopy Fittings
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-D01
Today I worked on making the slots in the hook angle so that I can make up the hook rail assembly.
1.42 hrs

Aug 23/14
Trimming the canopy
Type of Work: Construction
Category: Fuselage
Manual Reference:
After my first trimming and sanding I refit the canopy to the fuselage. I lined up the centering marks and fit the rear edge down to the support blocks. The rear edge fit about 1/2 of the distance around. I decided to work on the rear edge and layout the tape for additional trimming of the rear. After taping the rear edge I used 60 grit sandpaper to sand the edge back to the tape line, finishing with 220 grit. I had to make one more adjustment to the rear edge. Next I moved on to the front edge and re-taped it for trimming. The amount to be trimmed is a bit small for the band saw and a bit big for sanding but I decided to sand anyway. Now that the front and rear fit pretty well I marked the two sides and then trimmed them using the band saw.
8.86 hrs

Jul 27/14
Creating Tooling for Canopy Support
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-D01
Today I made up support blocks (tools) to support the canopy while trimming. I saw the concept in the EAA video showing how to trim a sonex canopy. I used the original patter than I used for the turtle deck. I traced two blocks onto a piece of MDF. After trimming the blocks on the bandsaw, I worked on the profile which changes from the bottom to the top.

Pattern
Pattern
Tooling Installed
Tooling Installed
Tooling Profile
Tooling Profile
     
1.88 hrs

Jun 30/14
Installing Skybolts and Windshield Strap to Firewall
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F17
1.87 hrs

Jun 29/14
Installing Skybolts and Windshield Strap to Firewall
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F17
1.29 hrs

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