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
Built turtle deck forming blocks
Type of Work: Tooling
Category: Fuselage
Manual Reference:
Today I made the turtle deck forming blocks. These were made in the same fashion as the rib forming blocks. The only difference was that I made both a left and right forming block to make the left and right hand turtle deck ribs.
Turtle deck patterns
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Patterns ready to be cut into forming blocks
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Cutting the forming blocks
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Turtle Deck Ribs
Type of Work: Construction
Category: Fuselage
Manual Reference:
I cut out the blanks for the turtle deck ribs from 0.025 aluminum
Turtle Deck Rib Lightening Holes
Type of Work: Construction
Category: Fuselage
Manual Reference:
I cut the lightening holes in the turtle deck ribs using a fly cutter. I tries some WD-40 as a cutting fluid which worked well except for being a bit messy.
Turtle Deck Ribs
Type of Work: Construction
Category: Fuselage
Manual Reference:
I deburred the lightening holes in the turtle deck ribs. This time I took extra care so that I would not have to redo this after the forming process.
Turtle Deck Forming Blocks
Type of Work: Tooling
Category: Fuselage
Manual Reference:
Tonight I started putting the flutting notches in the forming blocks for the turtle deck ribs.
Forming Flange on Turtle Deck Formers
Type of Work: Construction
Category: Fuselage
Manual Reference:
Today I started forming the flanges on the turtle deck formers using my forming blocks.
Cut Out The Last Of The Turtle Deck Formers
Type of Work: Construction
Category: Fuselage
Manual Reference:
I cut out the last two turtle deck formers today. These were the ones that go immediately behind the cockpit.
Cut Out Some More Turtle Deck Formers To Fix A Couple Of Mistakes
Type of Work: Construction
Category: Fuselage
Manual Reference:
I cut out a couple of additional parts today to replace two formers that I was not happy with. The number five former has not turned out well and I don't like the location of the straight bend in the one of the number 4 formers.
Another Number 5 Former
Type of Work: Construction
Category: Fuselage
Manual Reference:
I'm still not happy with the way the #5 former is turning out. I cant seem to get the center portion that is the highest point when installed to turn out right. It seems like it needs another flute or two. I tried again tonight with deeper flutes but it still didn't turn out.
The Last Copy Of The Number 5 Former
Type of Work: Construction
Category: Fuselage
Manual Reference:
I finally decided to add some additional flutes to the number 5 Former. I check the rivet locations and added to more recesses to my forming block. This time the former turned out great.
My first three attempts
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The added flutes
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The complete set of formers
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Started The Angle Clips
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F15-12L/R
Did the rough cutting of the angle clips.
C02-03 and F04-04 (Adjuster Strab and Spacer)
Type of Work: Construction
Category: Fuselage
Manual Reference:
I made both of these small parts from scrap left over from the 2.5" x 2.5" x 3/16" angle.
Cut To Length All Of The 2.5 x 2.5 x 1/8 Angle That I Had
Type of Work: Construction
Category: Fuselage
Manual Reference:
As the title suggests, I cut all of the angle to length. I started the SNX-F16-04 support angle and SNX-F10-05L/R seat belt attach brackets. I have these complete except for the pilot holes which are marked
Upper Motor Mount Angle
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F15-01l/R
Completed all of the trimming and started the clean-up of the first motor mount angle.
Rough Cutting
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F15-01L/R
I rought cut one side of the second upper motor mount today.
Finishing The Upper Motor Mounts
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F15-01L/R
Started today by finishing the upper motor mounts. The only thing remaining is to drill the holes and make any last minute trimming during assembly
Lower Motor Mounts
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F15-02L/R
Started to work on the lower motor mounts. I scaled the drawings to determine the dimensions and recorded them on a scrap of paper. I was then able to get on of the mounts to the rough cut stage using the band saw.
More Rough Cutting Of The Lower Motor Mounts
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F15-02L/R
After a break I started on the opposite side lower mount. Again, I managed to get the rough cutting done.
Finishing the lower motor mounts
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F15-02L/R
Back at it again for a fourth time today. I worked at the finishing of the motor mounts. I managed to get both of them almost complete. I just have the V notch on the top to finish and then, of course, the drilling. I think I may wait on the drilling until later but I'm not sure. I think a photo copy or a tracing would create a better template for the drilling rather than measuring but I'll decide that later.
Finishing The Lower Motor Mounts
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F15-02L/R
I finished the lower motor mounts by sanding the V-groove and then using scotchbrite to clean up all of the cut surfaces. I still need to drill the mounts.
Rough Work And Some Finishing
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F15-07L/R
I started rough cutting the left and right hand flap drive mounts. I also did some finish fileing on one of the mount. These are much simpler parts compared to the motor mounts.
Finishing Work On The Flap Drive Mounts
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F15-07L/R
I finished the flap drive mounts using 220 aluminum oxide sand paper and then a scotch brite pad. This is becoming pretty standard for all of these fittings. I also marked the holes
Finishing The Angle Clips
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F15-12L/R
I sanded and buffed the angle clips.
Made The Shoulder Belt Attach Fitting And The Rudder Stops
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F23-08 & SNX-F26-08
Using some of the off cut scrap from the angle I made the shoulder belt attach fitting and the rudder stops. These were fairly simple pieces that are essentially flat. I finished both of these except for the holes. I've decided to leave most of the drilling for later as the exact location of holes may be influenced during fit up.
Rough Work On The Forward Lower Mount Fitting
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F23-00
Cut out the forward lower mount fitting.
Finishing Forward Lower Mount Fitting
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F23-03
Finished the forward lower mount fitting.
Rough Cutting The Aft Lower Mount Fitting
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F23-04
Did the rough cutting and some finishing of the aft lower mount fitting.
The finished mount
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Finishing Aft Lower Mount Fitting
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F23-04
Just as the title says; I finished working on the aft lower mount fitting
Aft Angle
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F22-05
I made the aft angle, start to finish.
Finished aft angle
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Rudder Pedal Mount Angles
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F15-04L/R
Did the rough cutting of the rudder pedal mount angles today.
Rough rudder pedal mount angles
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Finished the Rudder Pedal Mount Angles
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F15-04L/R
Did the finishing work on the rudder pedal mount angles
Seat Belt Attach Angles
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F14-12L/R
I made the seat belt attach angles today.
Upper Forward Cross Tie
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F16-09
Cutout and started to work on the upper cross tie.
Finished The Upper Cross Tie
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F16-09
I started today by finishing the upper cross tie.
Attach Angle
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F10-19
Made the attach angle as well today.
Started the Hook Angle
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-D02-14
I started work on the hook angle today. One think that I did different from the plans was to leave the slot created by the hook smaller than dimensioned. I had hear that this slot may need adjustment depending on the exact stack up of the longeron and other components when installed. I left the opening smaller so that I could custom fit the part at installation
Cutting More Angle
Type of Work: Construction
Category: Fuselage
Manual Reference:
I started cutting up the 1.5 x 1.5 x 1/8 angle today. It looks like I will be one piece short but I have some scrap 2 x 2 x 1/8 that should be big enough so if I don't need to re-make any parts I will have enough.
More Work On The Hook Angle
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-D02-14
More work on the hook angle today. I also decided not to cut the slots until I was ready to install the angle so that they could be moved/changed if necessary. I finished the part and left it until installation.
Finished Cutting the 1.5 x 1.5 x 1/8 Angle
Type of Work: Construction
Category: Fuselage
Manual Reference:
The title says it all
Angle Fittings
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F03-05L/R
I made the left and right angle fittings.
More finished fittings
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Left / Right Hand Attach Fitting
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F03-06L/R
I worked at closing the angle for these fittings to 86.1 degrees using my vise. Next, I cut the and finished the ends
Starting at 90 degrees
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The angle is now 86.1 degrees (or close enough)
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Finished parts
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Finished parts showing the angle
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Forward Wing Attach Angles
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F14-08L/R
More closing angles to 86.1 degress. These pieces were considerably tougher due to the long length of the parts. Once closed they were rough cut and finishes.
Ready for work
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One angle closed
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Ready for the trimming
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Using the band saw to rip the angle
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After the first cut
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Marked for more cutting
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Rough work complete
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Catch All Entry
Type of Work: Construction
Category: Fuselage
Manual Reference:
I've worked on the angle over two weeks but I did not record my time. This is an estimate of what it took to finish with the 1.5 x 1.5 x 1/8 Angle
Cutting All The 1 x 1 x 1/8 Angle
Type of Work: Construction
Category: Fuselage
Manual Reference:
Two sessions of about 1 hr each was enough to cut 26 pieces from my 1 x 1 x 1/8 angle. I did not cut the 4 longerons but will leave these to the end.
Making Parts
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F08-10,-11,-08
I made three different small parts this time. These are starting to get easier.
Mark, Cut And Drill
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F13-03R
I started by cutting the angles on the end of this part then marking all of the pilot holes and started the drilling process.
R.H. Upper Longeron
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F13-03R
Completed the drilling of the small 3/32" holes. Started on the Oval hole. Used a 3/16" drill and a file.
R.H. & L.H. Upper Longeron
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F13-03L/03R
Finished the right hand large oval and started on the left hand longeron. Marked out the part, trimed the ends, marked the drill holes and started drilling.
L.H. Upper Longeron
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F13-03L
Completed the drilling and the large oval hole.
L.H. Upper Longeron
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F13-03L
Polished, sanded and marked the slots.
L.H. Upper Longeron
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F13-03L
I discovered that I had marked and cut the slots in the wrong spot so I had to start this part again. Cut the ends and marked for drilling
L.H. Upper Longeron
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F13-03L
Finished drilling the pilot holes. Made the large oval hole and marked and doubled checked the slots.
L.H. Upper Longeron
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F13-03L
I cut the slots today. I did this by drilling the end holes and then used a dremel cutoff wheel in my roto-zip to cut the slot. You need to be very careful or you break a lot of cutoff wheels.
L.H. Upper Longeron
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F13-03L
I completed the longeron today.
Lower Longerons
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F13-06R/L
Started work on the lower longerons. Trimed the ends and started marking the holes
Lower Longerons
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F13-06R/L
Drilled the holes in the lower longerons.
Right Hand Lower Longeron
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F13-06R
Polished the longeron with scotch brite.
L.H. Lower Longeron
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F13-06L
Polished the L.H. longeron with scotch brite.
R.H. Forward Angle
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F14-02R
Trimed the upper end of the angle
R.H. Forward Angle
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F14-02R
Trimed the lower end of the angle.
L.H. Forward Angle
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F14-02L
Cut and trimed the ends of the angle.
L.H. & R.H. Forward Angle
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F14-02L/R
Finished trimming the ends and polished the parts with scotch brite.
R.H. & L.H. Rudder Pedal Angles
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F14-07L/R
Rough cut both ends of the parts.
L.H. & R.H. Rudder Pedal Angles
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F14-07L/R
Finished the ends, drilled the parts and then polished with scotch brite.
R.H. & L.H. Horizontal Angle
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F14-13L/R
Marked and cut out the angle, then drilled and scotch brited the parts.
L.H. Gear Attach Angle
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F14-11L
Cut out the angle.
L.H. & R.H. Gear Attach Angles
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F14-11L/R
Cut out the right hand angle then worked at drilling and scotch briteing.
Lower Forward Cross Tie
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F16-10
Rough cut the angle and finished one end.
Lower Forward Cross Tie
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F16-10
Finished the other end. Filed, sanded and scotch brited the part.
Forward Angle
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F22-06
Marked, cut, sanded and then marked the pilot holes. Drilled the pilot holes and scotch brited the part.
Cutting 3/16 inch Aluminum Sheet
Type of Work: Construction
Category: Fuselage
Manual Reference:
I started to cut out parts from the 3/16" 6061-T6 sheet. The simplest approach seemed to be to cut out strips and create blanks in various sizes to allow for the parts to be cut. I cut two 1" wide strips and marked a 2-1/4" wide strip. I also marked the SNX-T12-07 Forward Attach Fitting for later cutting.
Left Hand and Right Hand Upper Horizontal Splice
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F26-05L/R
I cut, filed and sanded one blank. It's now ready for drilling, chamfering and forming.
Creating Cad Templates
Type of Work: Tooling
Category: Fuselage
Manual Reference: SNX-F26
This morning I drew up 3 parts in AutoCAD. I needed templates for the upper and lower horizontal splice plate and the lower vertical splice plate. These were fairly easy to create in AutoCAD. I printed a hard copy, glued them to white bristol board and cut them out for templates
Making Splice Plates
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F26
This afternoon I worked on making the splice plates from aluminum plate. I traced out the templates and cut the parts using my bandsaw. The bench sander cleaned up the edges nicely. I still have alot of work to do on these parts and it will probably take several hours to get them ready for forming.
Lower Horizontal Splice Plates
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F26-06L/R
Today I worked on the splice plates again. I used my bench sander and a sanding drum in the drill press to get the plates to the correct size. Next, a little filing to smooth out the ridges left by the bench sander. Finally, I finish sanded the parts and then used some scotch brite to polish them a bit. I still need to drill the holes, put on the chamfers and then bend the plates.
Splice Plates at Various Stages
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The Lower Horizontal Splice Plates I Worked on Today
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Splice Plates Waiting For Sanding
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Splice Plates That Still Need To Be Cut Out
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More Work on the Splice Plates
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F26-04/05/07 L&R
I finished cutting out the -04 splice plates using the band saw. Next, I used the bench sander to clean-up the straight sides on each of the splice plates.
Right and Left Hand Upper Horizontal Splice Plate
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F26-04L/R
Today I worked on the -04 splice plates. I used a file to clean up the edges after sanding. Then I sanded the edges to remove any remaining file marks. Finally, I finished the edges with a scotch brite pad.
Upper and Lower Vertical Splice Plates
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F26-05/07 L&R
I cleaned up the -05 and -07 splice plates today. I filed the edges and then sanded the edges. Next, I added the chamfers and pilot drilled all of the splice plates includeing the -04 and -06.
Splice Plates With Chamfers Ready For Forming
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Bending the Lower Vertical Splice Plates
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F26-07
I used the rod or pole bender in my vice to put the bends in the -07 splice plates today. I ended up with a little orange peel which I cleanup using a scotch brite pad. I am going to need to get some more dowels or buy a couple pieces of steel rod. I find that the hard wood doesn't last very long in the vise. I had to cut some new pieces for the second splice plate as the first pieces were becoming flat.
Ready To Start Bending
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Another View Of The Pole/Rod Bender
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Top View, Note The Tangent Marks
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Left and Right Hand Lower Horizontal Splice Plate
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F26-06L/R
I formed the bend on these two parts. I noticed that the hardwood dowels I have been using were being crushed with use so I switched the one on the inside of the bend for a 1" OD socket. This seemed to work well. As usual I ended up with a bit of orange peel on the surface that disappeared with an application of scotch brite. I had a hard time guessing at the spring back and ended up over forming the parts a little. A few taps with a rubber mallet brought the bend back to the correct angle.
Almost Ready To Bend. The Part Is In Backwards. Measure Twice, Bend Once.
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Left and Right Hand Upper Vertical Splice Plates
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F26-05L/R
I formed these parts as well. I started by marking the tangent lines and then formed them the same as the others.
Before And After Scotch Brite.
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Idler Plate
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F10-22
With all of the splice plates completed I started on the idler plate. It was fairly simple to cut out and create the radii on the ends. I have it marked for drilling but I need to determine the diameter for the last hole. It takes a fastener but the diameter is not marked. I'll have to lookup the correct size and decide if I want to ream the hole or just drill to size. I think reaming would be a good idea as it will ensure a tight fit for the hardware. I don't want any slope in the control system.
Two Holes Marked For Drilling
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Idler Plate
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F10-22
I drilled 3 pilot holes in the idler plate. All are 3/32" dia. I'm not exactly sure what size to drill the final holes. Two of the holes are called out at 1/4" and one is for an AN3 bolt. I haven't figured out what goes in the 1/4" holes and I have found conflicting information on the AN3 bolt. Some literature says to drill it 3/16" and some info says I should drill it smaller so that I have a tighter fit on the bolt. I left the part with the pilot holes and will open them up later.
Spacer Block
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F10-20
I made the small spacer block. It was fairly straight forward. I used the bandsaw to cut the material and then files, sandpaper and scotch brite to finish it.
Flap Handle
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-C04-07
I made the flap handle today. Using one of the previously cut strips, I cleaned up the edge using the vixen file. I then cut the strip to length and added the radii at the ends using the bench sander. A little sanding, bend and scotch brite and the handle was complete.
Brake Handle
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-L05-05
I followed the same process as for the flap handle and this part comleted fairly quickly.
Cutting 1/8 Inch Aluminum Sheet
Type of Work: Construction
Category: Fuselage
Manual Reference:
I started today by cutting strips from the 1/8" aluminum sheet to be used for fittings.
1/8 inch plate all cut into strips
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Fitting
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F03-03
I made a template and rough cut one fitting on the band saw.
Fitting
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F03-03
I continued work on the fittings today.
The Fittings and the Template
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Fitting
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F03-03
I worked some more on the fittings today. Again working from a rough cut part to a near finished part.
Trim Lever
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F08-09
I cut, filled, sanded and drilled the trim lever. I still haven't sorted out the exact drill sizes for AN3 and AN4 hardware yet so I stuck with pilot holes for the time being. I also put the first two bends into the lever. These are the ones that look like a joggle at the bottom where the cable attaches.
Longeron Doubler
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F13-04
I cut out the first longeron doubler and sanded it.
Longeron Doubler
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F13-04
I cutout the second doubler and sanded it. Next I drilled the pilot holes and then scotch brited both parts
Doubler Support Plate
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F15-14
I started this the support plate by making a template. I traced the part onto drafting paper then glued it to some bristol board and cut it out. I traced out 2 parts and cut them out on the band saw. Next I sanded them using a small sanding drum in the drill press.
Doubler Support Plate
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F15-14
I finished the support plates today by sanding and filling them to size then drilling the pilot holes.
Splice Plate
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F20-08
I measure the drawing and marked out the splice plate on the aluminum. I think this was a little quicker than making a template. The part is fairly square so this was easy. Next I cut it out on the band saw.
Splice Plate
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F20-08
I filled and sanded the edges of the splice plate to the finished shap then marked and drilled the pilot holes.
Attache Plates
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F20-09L/R
Again, I decided to lay these out by measuring the drawing instead of creating a template. After all the measuring for the first part I cut it out on the band saw. Next I started sanding in the 1 inch radius.
Attach Plates
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F20-09L/R
I finished filing the edges of the first attach plate then layout and cut the second one. Again, I filed and sanded the eddges. Next, I marked the holes on one of the parts then clamped them together for drilling. After getting a few holes drilled I used some colecos to hold the parts together while completing the drilling. Next, I marked the tangent lines and bent the parts to 30 degrees. I found that by overbending to 33 degrees I was able to get the parts exactly 30 degrees after spring back. I finished the parts with some scotch brite to remove the orange peel marks in the area of the bend
Lock Plate
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-D02-22
Again, cut, filed, sanded and drilled this small part.
Insert Plate
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-D02-23
A very simple part. Cut, file and drill.
Cross Tie Attach Plate
Type of Work: Construction
Category: Fuselage
Manual Reference: F07-06
Today I started working on all of the 0.090" thick components. I started by tracing the attach plate onto velum and then glueing it to cardboard to make a template. Next, I traced the template and cut out two pieces. I finished one of these with a file and sand paper
Cross Tie Attach Plate
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F07-06
I finished cutting out the second part, filed and sanded it to size. Next I marked and drilled all of the pilot holes in both parts and then finished the parts with scotch brite.
RH & LH Corner Plates (for Instrument Panel)
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F07-07R/11L
I layed out and marked both parts then cut them out on the bandsaw. The usual filing, sanding and scotch brite finished the 07R and I started sanding the 11L. I stopped work on these parts at this point as I may alter the instrument panel. I'm working on an idea that will give me a little more room in the panel. While, it's probably not required I just makes me feel better.
Gusset Plate
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F10-24
This was a fairly simple part. I measured, marked, cut, filed, sanded and scotch brited both in fairly short order.
Gusset Spacer
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F10-25
Another simple pair of parts. I setup the fence on the band saw so that I could rip the spacer to the correct width. Next, I cut them to the correct length and filed and sanded the edges.
Gussets (12 pcs)
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F14-10
Again, I used the fence to cut a bunch of 1-1/2" pieces. Next, I filled the two finished edges and marked the remaining cuts. Using the band saw I finished cutting the pieces to size then used the bench sander and a file to finish the edges.
Gussets (12)
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F14-10
I marked pilot holes and drilled all of the parts. Next I finished the parts by sanding and using scotch brite.
Doubler - Flap Access
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F15-06
I made template for this part using my velum and cardboard. The template was then traced onto the aluminum sheet and cutout on the band saw. I used the bench sander bring the doubler to the final size.
Doubler-Flap Access
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F15-06
To cutout the center of these doublers I drilled a 1/4" hole near the edge and then used a coping saw. It takes a while but it does work. I went through a couple of blades. In the end I found that an application of candle wax like I have been using on the band saw helps things along. I need to apply the wax several times. Once the parts were cut out I used a file for the straight edges and a sanding drum in the drill press for the curves. This cleaned things up nicely. I finished the edges with 220 grit sand paper and some scotch brite. For sanding the inside curves I wrap the sandpaper around a 1/2" socket extension. This seems to work well.
Doubler
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F15-06
Today I makred and drilled the pilot holes on both doublers.
Doubler
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F15-06
I finished both doublers with scotch brite.
Lower Gear Gusset Plate
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F15-09
I made templates for the gusset plate then traced it onto the aluminum. Cut the aluminum on the band saw and then sanded the part using both the bench sander and a sanding drum in the drill press. I finished the edges with a file and 220 grit sand paper. Next I marked and drilled the pilot holes and then finished the part with scotch brite.
Upper Gear Gusset Plate
Type of Work: Construction
Category: Fuselage
Manual Reference: SNF-F15-10
These were made in a maner similar to the low gear gusset plates.
Seat Belt Gusset Plate
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F15-11
These were fairly simple gussets. I measured and layed these out directly on the aluminum. Cut the parts on the band saw and filed and sanded the edges. Marked and drilled the pilot holes and then applied scotch brite.
Shear Plates
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F16-07
Again, these were simple parts that were layed out, cut, filed and sanded and the marked and drilled.
Spacer
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-F22-07
These were very simple rectangular spacer. I used my fence and ripped the two pieces to the correct width then cut them to length. A quick file and sanding of the edges finished the parts
Cut Strips
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-G01
I cut strips from 0.060" thick 6061-T6 Aluminum to be used for fuel tank straps.
Worked on Forward Fuel Tank Strap
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-G01-08
I cleaned up the edge of the strap and cut the radius on one end.
Forward Strap
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-G01-08
Finished the work on the forward fuel tank strap.
Rear Fuel Tank Strap
Type of Work: Construction
Category: Fuselage
Manual Reference: SNX-G01-05
I cut the ends of the strap then cleaned up the edges with a file. Next I marked and drilled the holes. Finally, I sanded and scotchbrited the strap.
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