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
Angle For The Vertical Stabilizer Main Spar
Type of Work: Construction
Category: Vertical Stabilizer
Manual Reference: SNX-T12-05
Next I made the angle for the vertical stabilizer's main spar. This was a faily simple part.
Cuts all marked out
|
|
|
More Cutting of 3/16 Inch Aluminum
Type of Work: Construction
Category: Vertical Stabilizer
Manual Reference: SNX-T12-07
I finished cutting out the strips of Aluminum and also rough cut out the SNX-T12-07
Forward Attach Fitting
Type of Work: Construction
Category: Vertical Stabilizer
Manual Reference: SNX-T12-07
I check the large end of the fitting to see that it was appropriately square with the centerline and then proceeded to file and sand the sides of the part. The next step is to cutout the slot in the fitting.
The Forward Attach Fitting After Sanding The Edges
|
|
|
Forward Spar Fitting
Type of Work: Construction
Category: Vertical Stabilizer
Manual Reference: SNX-T12-07
Tonight I cut the slot in the fitting. Then I started filling and sanding the slot to the finished size.
Forward Spar Fitting
Type of Work: Construction
Category: Vertical Stabilizer
Manual Reference: SNX-T12-07
Today I finished the sanding of the fitting. I trimmed the ends to length and then I formed the 35 degree angle. I used the traditional dowel and vise forming process. Have a look at the pictures to see what I mean. I think the part turned out pretty good. There was a little orange peel around the bend but a scotch brite pad cleaned that up nicely. I should mention that you have to overbend the part and then release it to get the correct angle.
The Dowel and Vise Forming Rig
|
Top View Of Formed Part After Releasing The Vise
|
|
Main Spar Aft Strap
Type of Work: Construction
Category: Vertical Stabilizer
Manual Reference: SNX-T12-01
I took one of the strips that I had previouly ripped to width in my band saw as a starting point for this part. I cleaned up one side using the vixen file. My long straight edge was helpful in ensuring that the edge remained straight as I filed. After filing and sanding I setup the band saw and trimed the strip again to get closer to the 2-1/4" width. Next, I filed the other side of the part to get the final width. I squared up one end and then marked the cut for the finished length.
Main Spar Aft Strap
Type of Work: Construction
Category: Vertical Stabilizer
Manual Reference: SNX-T12-01
I finished cutting the strap to length then I marked the two slots. Using my bandsaw I cut out the two slots and then used a sanding drum in the drill press to clean up the ends of each slot. Next I used the vixen file to cleanup the slots. I sanded the slots using a piece of 220 grit aluminum oxide sandpaper wrapped around a 1/2 inch drive socket extension. I finished the part with scotch brite and then started to layout the pilot hole locations.
After Cutting To Length
|
Rough Cut Slots
|
Finished Slots
|
Some Pilot Holes Marked
|
|
|
Aft Main Spar Strap
Type of Work: Construction
Category: Vertical Stabilizer
Manual Reference: SNX-T12-01
I finished the strap by marking and drilling the pilot holes.
The Finished Spar Strap
|
|
|
Spacer
Type of Work: Construction
Category: Vertical Stabilizer
Manual Reference: T09-03
Cut, file and sand to complete this part.
This is a catch all entry.
Type of Work: Construction
Category: Vertical Stabilizer
Manual Reference: Stabilizer
Back at the begining of December I started working on the vertical stabilizer. I cut out the remaining parts from the formed metal kit. Next it drilled the necessary holes and colecoed it all together. Finally, yesterday I rivited the assembly together to make the first real airplane looking assembly.
Disclaimer:
This web site is NOT owned or managed by Sonex, Ltd.
Sonex, Ltd. is not responsible for the content unless explicitly stated.
This web site is in no way a publication of Sonex, Ltd. or any other corporation.
All products mentioned are not necessarily recommended for use, but are included for
informational purposes only. All builder's tips and supplemental instructions represent
only the means by which the builder of the airplane shown in this website chose to
build his airplane. Builders tips and instructions are not meant to replace the plans
and instructions from Sonex, Ltd. All Builder's tips and instructions are presented only
as a source of information and a forum for exchange and the sharing of ideas and construction
methods. NO responsibility or liability is assumed, expressed, or implied as to the
suitability, accuracy, safety, or approval thereof. Any party using the suggestions,
ideas, instructions or examples from this website does so at their own risk and discretion
and without recourse against anyone. The owners and authors of this website are not
responsible for any product, builder's tips misuse, incorrect construction, or design
failure, nor any other peril. Any material from this website may be reprinted without
permission for non-commercial use, but please give credit to the author. Re-use of any
material from the pages within this web site (text or graphics) for commercial gain is
expressly prohibited without prior written permission from the web page administrator
and original author, artist or owner of the specific item being re-used.
