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.
Builders Log Entries
Elevator Ribs
Type of Work: Construction
Category: Elevator
Manual Reference:
I cut out three elevator rib blanks today. These were the first parts I've cutout without templates. I just laid out the parts using the dimension on the plans. I had a problem when I formed the first one. The second bend causes the first flange to come in contact with the bending brake. It hit a sharp edge and ended up with a gouge in the aluminum. I think I'll make this part again and see If I can get a short piece of 3/8" x 2" or 3" cold finished flat bar to make a new slimmer clamping bar for the brake.
Blanks, master on the right
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Triming the blanks
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Cut Out More Elevator Ribs
Type of Work: Construction
Category: Elevator
Manual Reference:
I cut out three more elevator ribs tonight.
More blanks ready for forming
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Forming Elevator Ribs
Type of Work: Construction
Category: Elevator
Manual Reference:
Using the new clamp bars for my bending brake I formed four elevator ribs. Somehow I got a piece of steel shaving embedded in the edge of one and decided to discard it. This also prompted me to clean up the shop a bit. I also discarded the first rib I had formed on the weekend as it ended up with a crease on the inside of one of the flanges when I tried forming it with the 1/2" clamp bar.
Stabilizer ribs
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Completed Elevator Ribs T07-02/03
Type of Work: Construction
Category: Elevator
Manual Reference:
I finished cutting out two more elevator ribs and forming all of them. I also started to layout and cutout the elevator root ribs T07-04L/R.
Finished Forming The Last Of The Ribs
Type of Work: Construction
Category: Elevator
Manual Reference:
Today I finished forming the last of the ribs required for the elevator, ailerons, flaps and rudder. Here they are all layed out on the bench. The only thing remaining is the small joggle in the end ribs for the fiberglass tail tips.
The remaining ribs
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Elevator Root Ribs
Type of Work: Construction
Category: Elevator
Manual Reference: SNX-T07-04 L/R
Two days in a row!
Today I began to look at the elevator. I started by digging out the box containing my formed metal and locating the root ribs. I checked the overlap on the front for the skins to be sure that the overlap was sufficient to allow for the correct drilling and edge distances. They both looked good.
After looking at all of the ribs I had previously made I discovered that the root ribs were made from 0.025 material instead of 0.032. I proceeded to make new root ribs. I had the original templates so it was fairly easy. I just traced out the ribs, drilled the relief holes, cut out the ribs, and cleaned up the edges using a file, sandpaper and scotchbrite. Next, I marked the bend lines and formed the ribs.
The next time out I'll need to start trimming the skins.
Riveting the Elevator
Type of Work: Construction
Category: Elevator
Manual Reference: SNX-T02
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