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.

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 997.24
Planning / Misc 6.10
Tooling 17.63
TOTAL 1020.97
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Canadian Aviation Regulations
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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
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Sonex Ltd.
Aero-Conversions, Inc.
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The AeroElectric Connection
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XCOM Avionics


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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

Jan 3/15
Drilling Gear Legs Continued
Type of Work: Construction
Category: Landing Gear
Manual Reference:
Today I continued the drilling of the gear legs. I removed the left main gear leg and repositioned it at the drill press to up drill from 1/8 inch to 1/4 inch. I used a new drill bit as the previous one was damaged removing a broken drill bit earlier. I up drilled both gear legs. The last step will be to up drill the axles and bolt everything together.
0.62 hrs

Dec 31/14
Drilling Main Gear for Axles
Type of Work: Construction
Category: Landing Gear
Manual Reference: SNX-L02
0.65 hrs

Dec 26/14

Type of Work: Construction
Category: Landing Gear
Manual Reference:
0.37 hrs

Dec 13/14
Axle Weldments
Type of Work: Construction
Category: Landing Gear
Manual Reference: SNX-L01
I started by comparing the purchased gear axle weldments with the drawings to determine what holes were missing. The first hole missing is the 3/16 inch pilot hole for mounting to the gear leg. Instead of drilling all the way through I drilled a 1/8 inch hole through the front side of each weldment only. This way I will be able to use the 1/8" hole to mark the pilot that I will drill through the gear leg. When I mount to the gear leg I will up drill to 1/4 and then make sure everything is aligned before drill through the back side of the weldment.
0.55 hrs

Nov 30/14
Preparing Titanium for Landing Gear
Type of Work: Construction
Category: Landing Gear
Manual Reference: SNX-L01
Today I continued working on the titanium bars for the main gear. I had previously cut about half way through the second gear leg. (Shortening the purchased 36 inch lengths to 34 inches). I purchased some new hacksaw blades. The recommendation for cutting titanium is to cut slowly but use an aggressive cut. I bought some 18 teeth per inch bi-metal blades. This blade worked well and I was able to get the second half of the bar in about 10 minutes. I would estimate about 20 minutes per main gear leg and 10 minutes maximum for the tail wheel.
0.34 hrs

Nov 29/14
Gear Legs
Type of Work: Construction
Category: Landing Gear
Manual Reference:
I order the Titanium for the gear legs from Titanium Joe. Their website sells titanium by the foot. I ordered two pieces of 1.125 inc diameter 6AL-4V by 36 inches long and one piece of .625 inch diameter 6AL-4V by 24 inches long. All three need to be cut to size. The titanium arrived two days after I ordered it. This weekend I started to work on cutting the pieces to length. I cut the 5/8 diameter titanium using an only manual hacksaw with an old blade. I used a fairly heavy pressure when cutting and kept to slow cuts. This seemed to work the best. Rather than cut with a level saw blade I worked the blade angle to cut at both the front and the back of the cut to keep the area being cut at any one time to a minimum. The pressure on the saw was just enough that the blade would distort during the cut. It took about 15 minutes to cut the 5/8 piece and about 30 minutes to cut through the first 1-1/8 inch piece. I used a new blade for the first 1-1/8 piece.
0.94 hrs


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