Sonex in Flight, click for home.

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.

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 also building the Sonex with standard gear and a single centre stick.

I need to make some changes/repairs in the fuselage. I discovered that I must have missed note in View H-H on sheet F01. Today I'm going to drill out the rivets and install them from the opposite side so that the control triangle can be installed.

Today I worked on some tooling to help with the final triming of the canopy. I found that the toughest part of fitting the canopy was pulling  it into position along the fuselage sides. So, I made up some pieces of MDF that I could clamp to the sides of the fuselage using ratchet straps. The MDF ends up flush with the upper longerons and provides a surface that I can clamp to. I plan to clamp some AL angles to the MDF to hold the canopy in place for the final fitting before I start drilling holes. I'm also hoping that I can drill the canopy while it is clamped in place. I know a lot of builders use a ratchet strap to pull the canopy down into place but I find this distorts the canopy so I really want to let it side in place and just pull in the portion that aligns with the upper longerons.

I continued to work on installing the tail wheel. I reinstalled the tail wheel mount and proceeded to install and torque the fasteners. I found that I needed an additional washer on each fastener to get the correct grip length.

I continued working on the main gear today. I removed the right hand axle from the gear leg and carefully marked the location for the cotter pin hole. I did this with the wheel and brake assembled to the axle and marked the location of the notch in the nut on the axle using a sharpie. The hydraulic brake drawings (SNX-L07) indicate that the hole for the cotter pin should be located after assembly. The SNX-L01 drawing shows this hole horizontal with respect to the axle assembly. I drilled the hole for the cotter pin and re-installed the axle stub on the gear leg. Next I greased the wheel bearings and installed the wheels. I left the cotter pins unbent in case I need to take the wheels off to work on the brakes.