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
Started On Tail Parts
Type of Work: Construction
Category: Horizontal Stabilizer
Manual Reference:
I started cutting out the blanks for the small tail leading edge ribs and forming them.
Relieving the forming block to get a 90 degree bend
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The first nose rib
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More blanks ready for forming
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Before bending
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After bending
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Another view of the flutes
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More Tail Ribs
Type of Work: Construction
Category: Horizontal Stabilizer
Manual Reference:
I formed up some more tail ribs today. I discovered that I really didn't need the holes in the leading edge ribs but they will actually be hidden. I formed the outer ribs for both the horizontal stabilizer and the rudder. I did these with only C-clamps holding the forming blocks together. This worked well and the parts turned out great.
Tail ribs - Opps, one extra nose rib - Better follow the plans
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Horizontal Stabilizer Fittings
Type of Work: Construction
Category: Horizontal Stabilizer
Manual Reference:
I started working with the fittings made from angle. The first part I picked was the forward spar fitting. This is made from a piece of 2-1/2" x 2-1/2" x 3/16" angle that has to be cut down quite a bit. I started by cutting a length of angle down using my hacksaw. Next I marked up the first cuts and used my band saw. I need to get a proper blade as existing blade only has about 6 teeth per inch and wanders a fair bit. After cutting the angle I next used my files to clean up the cuts. Again, I discovered that I really need a vixen file.
Halfway throught the first cut
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Now to finish the cut on the other leg
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Marked for the band saw
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Another view before cutting on the band saw
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After cutting
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Time for a new blade. This wood blade wanders too much.
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Ready for the files
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Right side done, now for the left
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A closer view of the right side
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More Cutting And Filing Fittings
Type of Work: Construction
Category: Horizontal Stabilizer
Manual Reference:
More cutting and filing away at the forward spar fitting.
Flange removed from both ends
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Narrowing the short flange
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Ready to file the narrow flange
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Filing complete
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More Work on Forward Spar Fitting
Type of Work: Construction
Category: Horizontal Stabilizer
Manual Reference: SNX-T03-06
I've spent more time completing the Forward Spar Fitting and started work on the Main Spar Fitting SNX-T03-02
Main Spar Fitting
Type of Work: Construction
Category: Horizontal Stabilizer
Manual Reference: SNX-T03-02
Continued work on the Main Spar Fitting.
Angles For The Horizontal Stabilizer Rear Spar
Type of Work: Construction
Category: Horizontal Stabilizer
Manual Reference: SNX-T03-03
The final exercise for today was to make the angles that attache to the horizontal stabilizer rear spar. These required a bend with an inside radius of 1/8" tangent to the inside radius of the angle. To bend this I found a screw driver shaft that was the correct diameter and clamed the angle to a plate in the vice. Next I attached a piece of hardwood to provide the leverage for the bend. This seem to work okay but it did cause the angle to bend a little on the adjacent leg. I solve this problem with a few blows from my rubber mallet after the initial bending.
The lever attached
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Another view of the lever
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Angle clamped for bending
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Another view of the clamping arrangement
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Close-up of the clamping
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Finished Parts
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Main Spar Forward Strap
Type of Work: Construction
Category: Horizontal Stabilizer
Manual Reference: SNX-T12-02
Drilled the main spar forward strap
Drive Horn
Type of Work: Construction
Category: Horizontal Stabilizer
Manual Reference: SNX-T13-03
I finished bending the drive horn. I find it difficult to estimate the amount of overbend required. In this case I went a little beyond and had to hammer the bend back a bit.
With the bend complete I used scotch brite again to clean up the orange peel like marks in the area of the ben.
Forward Root Clip
Type of Work: Construction
Category: Horizontal Stabilizer
Manual Reference: SNX-T06-5
I cut out and formed one of the forward root clips.
Second Forward Root Clip
Type of Work: Construction
Category: Horizontal Stabilizer
Manual Reference: SNX-T06-05
I cut out the second clip then formed it on the brake. Next I polished it and drilled the holes.
Drawings for Elevator Horn Weldment Parts
Type of Work: Planning / Misc
Category: Horizontal Stabilizer
Manual Reference: SNX-T06-01
It's been a while since I've had a chance to work on the plane. I have ordered and received almost all of the 4130 steel for the weldments. Today I fired up AutoCAD and drew two of the parts required for the Elevator Horn Weldment; the Drive Plate and the Drive Arm. I don't like the idea of cutting up my plans and while I could trace these parts I find it more interesting to draw them in AutoCAD and the plot out the templates. This is probably way more accurate than required but it works for me
More work on the parts for Elevator Horn Weldment
Type of Work: Construction
Category: Horizontal Stabilizer
Manual Reference: SNX-T06-01
I bought a new band saw blade from a local vendor in the Brampton, ON area. They make blades to order ,so I purchased a 1/2" wide by 0.025" thick 14-16 variable pitch bi-metal blade. It seems to cut the 4130 plate fairly well but I'm having difficulting cutting tube. I think I'll use a zip disk in a small angle grinder to cut the tube. My other thought for the tube is do put an abrasive disk in my power miter saw. In any case my bench sander works great to put the angle on the end of the tube.
I cut out the two plates required for the elevator horn and I drilled the pilot holes in one. I also sanded the 20 degree angle into one end of a piece of tube.
Working with the 4130 seems similar to working with the aluminum althought its a bit heavier and takes a little more force to get things cutting.
Forward Spar Channel
Type of Work: Construction
Category: Horizontal Stabilizer
Manual Reference: SNX-T03-06
Today I started working on the forward spar channels. After digging though my formed metal kit I located a 96" length of Z03-02 channel. I cut it to length using a hacksaw and snips and then trimmed the end in preparation for forming. Trimming the end involved using one of my small round files and a little sandpaper. The left and right handed snips come in handing working on this material. Next I formed the 68 degree angle on the end. I finished todays work by marking the piece for drilling. I also did some mock setup just to see how the part fits up.
Forward Spar Channel
Type of Work: Construction
Category: Horizontal Stabilizer
Manual Reference: SNX-T03-06
Today I continued work on the forward spar channels. I lost my cut length for the channel so I had to recalculate it. Next I cut, trimed and formed the second channel. Finally I drilled both and then removed the protective plastic coating.
The Two Forward Spar Channels
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Main Spar Channel
Type of Work: Construction
Category: Horizontal Stabilizer
Manual Reference: SNX-T03-04
I started making the main spar channels for the horizontal stabilizer. I located my last piece of Z03-02 channel then calculated the cut length and cut the channel. Again, I used a hack saw to start the cut on the web of the channel and then finished the cuts in the flanges with snips. I used my bench sander to clean up the ends. Next I trimed the end using right and left hand snips and filed the 1/8" radius. I finished the session by putting the 90 degree bend in the end of the channel.
Trim Tab
Type of Work: Construction
Category: Horizontal Stabilizer
Manual Reference: SNX-T07-05
I layed out the trim tab on a piece of .032" aluminum base on the dimensions from the planes. Used the Wiss snips to cut out the trim tab and then filled sanded and scotch brited the edges.
Cable Attach Plate
Type of Work: Construction
Category: Horizontal Stabilizer
Manual Reference: SNX-T07-07
Today I worked on making the cable attach plate. This part has no dimensions and the plans say that you need to make it from the full size print. I a technique that I use for these types of parts.
- Start with a piece of drafting paper. It is see through and makes good tracing paper.
- Place the drafting paper over the print and trace the part. I don't usually tape the paper down but rather mark a couple of reference points so that I can relocate the paper if necessary.
- After tracing the part including any hole locations, I use a glue stick to glue the drafting paper to a piece of bristle board. I then cut out the bristle board and I have a cardboard template for the part.
- I use the template to trace the part onto the aluminum and then use a center punch to mark all of the holes.
Now the process is the same as making any other aluminum part.
Drafting Paper Over the Plans
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Part Traced Onto The Drafting Paper
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Drafting Paper After Tracing
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Glued to Bristle Board
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Finished Cardboard Template
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Trim Tab Assembly
Type of Work: Construction
Category: Horizontal Stabilizer
Manual Reference: SNX-T07-05
Today I worked at finishing the trim tab assembly. No real magic here. The plans allow a -3 hinge instead of the -1 so I used up a piece of the hinge that was left over from the rudder.
Finished Trim Tab (Just needs the lock wire and holes for the hinge pin)
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Made New Tip Ribs for Horizontal Stabilizer
Type of Work: Construction
Category: Horizontal Stabilizer
Manual Reference: SNX-T14
When I started trying to fit the fiberglass tips to the horizontal tail I quickly discovered that they were very hard to fit between the tip ribs and the skin. It seems that there really isn't any designed in clearance in the plans. After several attempts I decided that the best approach would be to make new tips.
Using my cad program I made up a new drawing for the tip rib that allowed for 1/16 of an inch between the skin and the rib. I made up a new forming block and hammered out two new tip ribs. I used the old ribs to locate the 6 holes in each for the spars. Since the new ribs were smaller than the old ribs they would nest with the old ribs and allow me to easily mark the holes for the spare rivets.
After completing the new ribs the clearance was visible but the tips were still a snug fit. The next step will be to get the trailing ribs for the fiberglass tips made up and then to complete the fitting of the tips.
Right Side Horizontal Stabilizer Tip
Type of Work: Construction
Category: Horizontal Stabilizer
Manual Reference: SNX-T14-02
I completed the right side trailing tip rib. This consisted of aligning it with the existing holes in the tip rib and drilling new holes in the trailing rib. Next, I installed the tip and layed out the holes between the tip and the trailing rib. I drilled these and colecoed the tip in place.
Right Hand Horizontal Stabilizer Tip - Stabilizer Up Side Down
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Aileron Tip Rib
Type of Work: Planning / Misc
Category: Horizontal Stabilizer
Manual Reference: SNX-W04
Tonight I spent a bunch of time at the CAD system to create a 3D model of the aileron tip so that I could create my own pattern for the tip rib. I created a new sheet metal model of the rib and then created the flat pattern. Tomorrow I\'ll try fabicating it and see what happens. Screen shots and a drawing to follow if it works. Stay tuned.
Completing the Riveting of the Horizontal Stabilizer
Type of Work: Construction
Category: Horizontal Stabilizer
Manual Reference: SNX-T02
I completed all of the rivets on the horizontal stabilizer except for those at the tips. I left these for latter when I get ready to attach the fiberglass tips.
Finishing the Rivets on the Vertical Stabilizer
Type of Work: Construction
Category: Horizontal Stabilizer
Manual Reference: SNX-T08
Wrapping Tail for Storage
Type of Work: Construction
Category: Horizontal Stabilizer
Manual Reference:
Today I wrapped the tail components for storage. I noticed that some of the components had spots from the spiders in my garage so I decided it would be prudent to protect the exposed surfaces. I used some stretch wrap to wrap all of the components.
Wrapped Horizontal Stabilizer
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