Plans Arrived
Type of Work: Planning / Misc
Category: Planning and Paperwork
Manual Reference:
My plans arrived today. Wow! Are they ever professional looking. I've seen plans for other planes and these are the best so far.

Wing Rib Templates
Type of Work: Tooling
Category: Wings
Manual Reference:
Tonight I started working on the wing rib templates. Using AutoCad and the coordinate table contained in the Sonex plans I drew up the forward rib, SNX-W15-05. I created two versions of the template. One with the flanges to be used as a pattern for the aluminium blank and one without the flanges to be used for the forming blocks.

Wing Rib Templates
Type of Work: Tooling
Category: Wings
Manual Reference:
Again tonight I worked on my templates for the wing ribs. This time I created the Aft Rib SNX-W16-06.

Prepared Builders Log
Type of Work: Planning / Misc
Category: Planning and Paperwork
Manual Reference:
Today I setup my builders log in Microsoft Access. I took a look at Kit Log Pro and it looked like I could do the same thing using MS Access. I enhanced my database so that I can have as many pictures as I like with each entry. The only issue I can see at the moment is that I may not be able to print two photos per page. If I have text and one or more photo the first photo shows on the first page but the next one is forced to the following page due to the space available.

Cut-out templates for Nose Ribs
Type of Work: Tooling
Category: Wings
Manual Reference:
Today I cut out the templates for the nose ribs. Next, I need to decide whether to try a router to cut the aluminium or to use the snips. If I go with the snips I'll need to glue the templates to bristle board and then use bristle board as the template. If I decide to use the router I need to cut out two pieces of MDF to sandwich the aluminium between and then use as a guide for the laminate trimmer bit.

Began working of first rib
Type of Work: Construction
Category: Wings
Manual Reference:
Tonight I cutout the first rib (SNX-W15-05). I used a set of Andy Snips. These worked amazingly well. In the past I have use either left or right hand aviation snips and these would leave serations along the edges. This meant that I had to cut the blank a considerable amount oversize and then file it to size to remove the serations. The Andy Snips leave no serations to be cleaned up. A quick file and the cutout blank was ready to go. I drilled the two tooling holes and then setup my fly cutter. I am not happy with the pilot bit in the fly cutter. It seems to be off center slightly. I guess that's what I get for buying the cutter at home depot. In anycase, the 3" lightening hole was easy to cut. I can now see why everyone else works in a batch mode. It makes sense to cut out the blanks then setup for the lightening holes and drill them all at once with the setup still in the drill. I plan to finish the current rib and then start working on a batch.

Work on wing ribs
Type of Work: Tooling
Category: Wings
Manual Reference:
I worked on the forming template for the nose rib. The template that I made in AutoCAD was glued to a piece of MDF. Next a second piece of MDF was cut out and clamped to the first one. I drilled the tooling holes and counter sunk them. The two pieces were then bolted together and the finished shape was cut on the bandsaw. I used the bench sander to finish the parts. Next I seperated the two pieces and used a router to put a round edge on one of the pieces. The band saw as set to 10 degrees and a fence installed. I then cut the forming block to provide a 10 degree relief to allow forming to the full 90 degrees. Finally, I transferred the flute positions from the plans to the forming block and then, using the drill press and a rasp bit, I cut the flute locations into the blocks.

Wing Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
Today I made the template for the ribs. SNX-W16-06. I used the same process as the previous entry. I also layed out a number of both ribs on my sheet of 0.025 aluminium. I rough cut out all of the blanks that I had material for and started to work on the finish cutting.

Cut Out Remaing Rib Blanks
Type of Work: Construction
Category: Wings
Manual Reference:
I cut out the remaining rib blanks. I picked up another sheet of 0.025 from Triangle Specialty Metals in Cambridge for this. The blanks were rough cut. I started to drill the relief holes. I'll try to finish them tomorrow.

Finished Cutting Out Nose Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
Today I finished cutting out the nose ribs. I completed all of the relief holes, marked up the -01,-02,-03, & -04 ribs and cut them out as well. I also started deburing.

Nose Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
Work progressed today on the nose ribs. They have all been deburred. I did this using a file and Scotch Brite pads. First I filed the edges to smooth them out. Next a chainsaw file was used in the tight radii to remove burrs. Finally, the Scotch Bright pad was used to remove any scratches along the edges left from the cutting process. This also helped to remove burrs from the edges. All of the parts were tested with my fingers to ensure no sharp edges remained. The next step was to stack all of the blanks and drill the tooling holes and the center hole for the fly cutter. The blanks were then unclamped and a large (1/2") drill bit was used to deburr these holes. I then setup the drill press for the 4" lightening hole with the fly cutter and began to cut these holes.

Cutting Lightening Holes
Type of Work: Construction
Category: Wings
Manual Reference:
Today was spent cutting lightening holes in the nose ribs. The fly cutter worked well. The longest part of the job was clamping and unclamping the ribs. I could have used some of the spring type clamps but since I don't have any, C-clamps had to do.

Forming Nose Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
I worked at hammer forming the nose ribs today. I had tried the previously without much success. Today I tried again. The first rib had very small flutes and the flange was not very straight. I tried using my fluting plyers to straighten the flange resulting in marks on the flange. I don't know if they will do any harm but I'd prefer not to use this rib. I also tried a flanging tool made with bearings for the lightening hole and this resulted in a rib that was even more bananna shaped. This rib will be scrapped. My second attempt was better but I still ended up with marks on the flange. I don't plan to use the fluting plyers on the flange again other than for fluting. Today I enlarged the reliefs on the forming blocks and tried again. I used a 1/2" socket extension to hammer the flutes and then the fluting plyers on the flutes to help straighten the rib. This seems to work and I ended up with two good rib. I will scrap the first two but I only have to make one new one as I made an extra anyway.

Forming Nose Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
More forming of nose ribs today. I managed to get four made in one hour. This is going to take a while but they are now turning out well.

More Nose Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
40 minutes and 4 more nose ribs tonight. I've got it down to 10 minutes per rib. I guess that means a total of 260 minutes to form all 26. Only 4 hrs and 10 minutes.

Rib Forming
Type of Work: Construction
Category: Wings
Manual Reference:
Two sessions of forming ribs today. I now have only 10 left to form.

Completed Nose Rib Forming
Type of Work: Construction
Category: Wings
Manual Reference:
This morning I completed the hammer forming of the nose ribs. I think I have one extra so I won't need to rebuild one of my early attempts that did not turn out. I still need to flange the holes. I ordered the flanging tool last week from Sonex so hopefully it will arive next week sometime.

Preparing To Cut Out Main Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
I started to drill the corner relief holes in the main rib blanks today. This is a very slow process, drilling four holes per blank.

Flanging Lightening Holes
Type of Work: Construction
Category: Wings
Manual Reference:
My hole flanging dies arrived today from Sonex. I tried flanging the lightening holes in the nose ribs. It seems to work okay but the ribs that started out flat are now slightly dished. I don't know if this is okay or if I'm doing something wrong.

Drilling Corner Relief Holes
Type of Work: Construction
Category: Wings
Manual Reference:
Drilled a bunch more corner relief holes in the main ribs tonight. I only have 6 left to finish.

Working on Main Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
Completed drilling the corner relief holes. Next I cut out the corners of all of the ribs. The next step will be to trim the remaining four sides of all the main ribs.

Continued Trimming Main Rib Blanks
Type of Work: Construction
Category: Wings
Manual Reference:
I completed trimming five main or rear rib blanks tonight. I also trimmed the front and rear flanges of all of the rear rib blanks. Only 21 more to trim. Hopefully, tommorrow I should get these done.

Trimming Rear Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
I completed the trimming of the rear ribs today. I also drilled all of the pilot holes for fly cutting the lightening holes and drilled the tooling holes.

Cutting Lightening Holes in Rear Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
I cut all of the 3" lightening holes in the rear ribs and started to cut the 4" holes.

30 Inch Bending Brake Purchase
Type of Work: Tooling
Category: Tooling
Manual Reference:
Today I purchase a 30" bending brake. The local Princess Auto store has these for $79.00 dollars (Canadian). I picked this one up in Hamilton, Ontario. It looks pretty sturdy and should do the job for all of the small parts. I plan on purchasing the pre-bent metal kit so I only need the brake for small parts. It was made in China but the quality is reasonable.

Finished Lightening Holes
Type of Work: Construction
Category: Wings
Manual Reference:
I finished cutting all of the 4" diameter lightening holes in the rear ribs today. That's 52 four inch holes. Wow. It seems like your forever putting aluminum under the drill. Not much to take pictures of so I didn't. Next I need to debur, trim the various ribs that have the larger relief and then I can get on with the forming. Oh yea, I also need to clean up some of the tape glue left over from the packing of the aluminum when I brought it home. Acetone seems to work best as long as I have my mask on.

Deburring Rear Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
It has warmed up a bit outside so I can now get the heat up in the garage. I started deburring rear ribs tonight. It seems to be a very slow process. I think its time to purchase a scotch brite wheel.

More Deburring
Type of Work: Construction
Category: Wings
Manual Reference:
It's quite cold out today (-17C) but I managed to get the garage up to 10. I deburred some more ribs today. I think I finally have it figured out. I'm using a deburring tool for the large lightening holes then a scotch brite pad to finish the holes. Next I use the scotch brite wheel in the grinder for the edges of the rib. It does a wonderful and quick job. Finally, a scotch brite pad just to finish things up. 7 ribs completely deburred, 19 more to go.

Duburring
Type of Work: Construction
Category: Wings
Manual Reference:
Four more ribs completed. The total now stands at Eleven. Only 15 more to go.

Wing Ribs
Type of Work: Construction
Category: Tooling
Manual Reference:
Over the last few days I have continued deburring the Wing Ribs. I got to the point where I had 10 left to deburr. At this point I decided I needed to make the -01 through -05 wing ribs. I marked each according to the plans. Drilled a new 1/4" relief hole and then made the extra cutout using the Andy Snips. I now have 10 ribs ready to be deburred.

Finished Deburring the Rear Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
Over the last two days I've managed to get in the time to complete the deburring of the main or rear ribs. I also used some acetone to remove the glue left behind by the tape that was used to secure the roll of aluminum when I brought it home in my van. I'll have to remember next time to only allow the supplier to use stretch wrap and not use the tape. It looks like I should be ready to get to forming next.

Add Fluting Notches To The Rib Forming Blocks
Type of Work: Tooling
Category: Wings
Manual Reference:
I started today by adding the fluting notches to my rib forming blocks. These were done using a rasp type bit in the drill press. I simply held the forming block at the appropriate angle and pushed it against the rasp bit. The finished notch works well.

Forming Rear Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
With the forming blocks ready to go I started to form the rear ribs. After clamping them between the forming blocks and putting the assembly into my workmate, its fairly easy to hammer over the flange. Working slowly so as not to stretch the aluminum too much I can almost get the flange completely formed before pushing material into the fluting notches. For the flutes I use a 1/2" drive socket extension and the same forming hammer. The flutes look very nice and the ribs come out almost flat.

Rib Forming
Type of Work: Construction
Category: Wings
Manual Reference:
Over the last two days I've managed to get a total of 13 ribs formed. Now I only have 13 more to form. I added an extra bolt to my forming blocks to help keep the middle of the blocks together. I found that even clamped in my workmate the blocks didn't seem to say together.

More Rib Forming
Type of Work: Construction
Category: Wings
Manual Reference:
Another 4 ribs formed today.

More Rib Forming
Type of Work: Construction
Category: Wings
Manual Reference:
Two More Ribs tonight. I also discovered that I have made one extra rib so I actually have 8 more to form.

Rib Forming
Type of Work: Construction
Category: Wings
Manual Reference:
Four more ribs formed today. Almost done! The ribs that is!

Finishing the Rib Forming
Type of Work: Construction
Category: Wings
Manual Reference:
I complete the rib forming today and moved on to the flanging. I managed to get all of the lightening holes flanged as well. I still have a little cleanup to do on the ribs. I noticed a few burrs that I didn't get cleanup up earlier. In any case, I'm nearly done with the ribs. Wow!

Deburring Again
Type of Work: Construction
Category: Wings
Manual Reference:
I spent a bunch of time today working on deburring the lightening holes in the nose ribs

More Deburring
Type of Work: Construction
Category: Wings
Manual Reference:
Spent time cleaning up the rear ribs

Rib Clean-up
Type of Work: Construction
Category: Wings
Manual Reference:
Today I worked at cleaning up the remaining 10 ribs. I got 4 done but discovered that one was damaged so I'll have to use a spare to make a new -02 rib.

More Rib Clean-Up
Type of Work: Construction
Category: Wings
Manual Reference:
I completed the deburring and cleanup of all but the last two ribs. I've been using a 330 grit aluminum oxide sandpaper to cleanup the inside of the lightening holes and than a 400 grit wet paper to cleanup the corner reliefs. To finish the job I use a scotch brite pad to buff all the edges to a nice smooth finish.

Rebuilt -02 main rib
Type of Work: Construction
Category: Wings
Manual Reference:
I made a new -02 main rib from one of my spares. I should have used the band saw to do the triming after drilling the relief hole, but I didn't think of it in time. Instead, I used my Wiss snips to do the triming. They worked but I think the band saw would have been quicker. Now I'm done with the ribs except for straightening and corrosion protection. I think I'll move on to some other parts for a while.

Templates For Rib Reinforcements
Type of Work: Tooling
Category: Wings
Manual Reference:
Using velumn, I traced the shape for the four different rib reinforcements. Next, I cut these out and glued them to bristol board. Finally, I cut out the bristol board to create my tracing templates.

Layout Of Rib Reinforcements
Type of Work: Construction
Category: Wings
Manual Reference:
Using the templates I made yesterday I started to layout the rib reinforecments. I had some scrap material left from cutting out the ribs. I managed to get all of the reinforecments to fit. At first I ignored marking the locations for the relief holes and simply cut out the reinforcements but it became obvious it would be better to draw in the relief holes when laying out the parts. This way I can drill all of the holes at once and then cut once.

Cut Out The Rib Gussets
Type of Work: Tooling
Category: Wings
Manual Reference:
This afternoon I cut out all of the rib gussets. Next I need to clean up, file and deburr the edges. Then I get to try out my bending brake.

Sanding and Deburring Gussets
Type of Work: Construction
Category: Wings
Manual Reference:
I started to sand and deburr the rib gussets today.

Rib Gussets
Type of Work: Construction
Category: Wings
Manual Reference:
I finished the sanding and deburring of the rib gussets and then formed them using my bending brake. I started by using my scotch brite wheel to clean up the around the relief hole. Next I used a block sander with 220 grit aluminum oxide paper to sand all of the edges smooth and square. A coarse scotch brit pad was used to finish the edges and the surface. With the part ready to be formed I started to work on the bending brake. I created a template to gauge the edge of the clamp bar. It needs to have a 1/16" radius filed into it. I put the clamp bar in my vise and with a file, created the necessary edge. With the clamp bar prepared I was ready to form the gussets. I drew the tangent lines on the gussets for the first 16 and then after a little experimentation formed them with the brake. For the last 16 I only marked each end of the tangent lines.

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 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.

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.

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.

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.

Cut Out More Elevator Ribs
Type of Work: Construction
Category: Elevator
Manual Reference:
I cut out three more elevator ribs tonight.

Made New Clamp Bars For The Bending Brake
Type of Work: Tooling
Category: Tooling
Manual Reference:
Today I purchased a couple of lengths of 3/8" x 2-1/2" cold finished flat bar from the Metal Supermarket. I had one piece cut to 15" long and I had one piece 30" long. From the 30" long piece I cut a 2-1/2" long piece. Next I ground a 10 degree angle along one edge. I finished the edge with a file and then put a 1/8" radius on the edge. The 3/8" clamp bar replaces the 1/2" that came with the brake. This allows me to form tighter bends when they are in the same direction as required for the elevator ribs. I also made sure that I radius the top edge so that it would not dig into the first flange when forming two tight 90 degree flanges.

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.

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.

Templates For The Remaining Ribs
Type of Work: Tooling
Category: Planning and Paperwork
Manual Reference:
I drew up the remaining tail, aileron and flap ribs using AutoCad. I then plotted these out full scale and glued them to bristle board to be used as templates.

Layed Out And Cutout Remaining Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
Using the templates I made earlier in the week, I layed out the remaing aileron, flap and tail ribs and cut them out.

Deburring
Type of Work: Construction
Category: Wings
Manual Reference:
I deburred all of the remaining ribs today. Now I just have to form them. I also ordered a set of offset seaming pliers to help form some of the sharp bends.

Formed Long Bends On Flap And Aileron Ribs
Type of Work: Construction
Category: Wings
Manual Reference:
The heading says it all. I will need to make up another short clamp bar for the bending brake to form the short flange on both ribs.

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.

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.

More Cutting And Filing Fittings
Type of Work: Construction
Category: Horizontal Stabilizer
Manual Reference:
More cutting and filing away at the forward spar fitting.

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.

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.

Upper and Lower Aileron Bell Crank Clevis
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W21-07/06
I worked on the aileron bell crank clevises today. I was able to make one from some of the scrap I generated when I was working on the motor mounts.

More Work On The Bell Cranks
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W21-06/07
I finished up the smaller set of aileron bell cranks today.

Cutting All Of The 2 x 2 x 1/8 Angle To Length
Type of Work: Construction
Category: Wings
Manual Reference:
I cut all of the 2 x 2 x 1/8 aluminum angle to length

Larger Aileron Bell Cranks
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W21-03/04
From the 2 x 2 x 1/8 angle I made the larger aileron bell cranks for the opposite wing. These are getting fairly easy with all the practice.

Marked out the part
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W20-03

More Work On The Root Rib Attach Angles
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W20-03
Worked at finishing up the second root rib attach angle. Again all but the holes

Spread The Raw Angles And Made The First Of Two Roo Rib Attach Angles
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W20-02
I started by opening up the angle of the material that I had cut to length. I started out using hardwood as shown in the pictures but quickly changed to a steel backup plate (with aluminum covering) when the hardwood broke. I also used some WD-40 as a lubricant to help the angle slide on the plate. The layout work was the same as the previous two parts so making the first one of these angles when fairly quickly.

Worked On The Second Root Rib Attach Angle
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W20-02
With the first angle done the second one did not take too long.

Made The Rear Root Rib Attach Angles
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W13-02L/R
I made the root rib attach angles for the trailing end of the root ribs. I started by opening and closing the raw angles to the correct angle. After getting the angles opened up and closed up correctly I layed out the cuts and finished the angles

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.

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.

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.

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.

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.

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.

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

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.

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.

Vertical Stiffener Angle
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W11-09
Marked, cut, filed, sanded and scotch brited the part.

Outboard Vertical Stiffener Angle
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W11-11
Marked, cut, filed, sanded and scotch brited the parts. Marked the pilot holes and drilled

L.H. & R.H. Tie Down Fitting
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W11-10L/R
Marked, cut, filed, sanded and drilled out the holes.

Main Spar Forward Strap
Type of Work: Construction
Category: Horizontal Stabilizer
Manual Reference: SNX-T12-02
Drilled the main spar forward strap

Main Spar Center Web
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W10-03
I cut out the blanks for the main spar center web from flat 1/8" sheet that I received from Aircraft Spruce.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

Left Hand and Right Hand Attach Plates
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W13-01L/R
I started with one of my previously created strips of aluminum that is almost the correct width. I cleaned up the long edges using the vixen file, mill file, sandpaper and scotchbrite. The brought the strip to the correct width. Next I started laying out the part using an ultrafine sharpie right on the aluminum. I had to measure one of the angles at the nose of the part as it was not dimensioned on the prints.

More Work Today On the Attach Plates
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W13-01L/R
Well, I got back at things again today. I find that an hour at a time is about right and gives me some thinking time. I finished marking out the attach plates and then cut them out on the band saw. I keep remembering to use a candle on the blade before any serious cutting and it sure keeps the blade clean. I used the bench sander after cutting to start cleaning up the edges.

Holes In The Attach Plates
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W13-01L/R
I started work on the large oval hole and the tail relief. On one of the attach plates I decided to drill a series of 3/32 inch holes around the perimeter of the large oval hole. Next, I used a coping (sp?) saw to cut between each of the holes and get a rough opening. Finally, I used a sanding drum in the drill press to start cleaning up the oval. I also used the band saw to cut the tail relief.

More Attach Plate Work
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W13-01L/R
I finished sanding the large oval hole. Next I setup a fence on my drill press to allow me to drill all of the 3/32 inch pilot hole in a straight line. I clamped a piece of hardwood to the drill press table 1/4 of an inch from the centerline of the drill bit. This lets me drill exactly 1/4 inch from the edge of the part. All I have to do is line up each of the marks measured from the end of the attache plate.

The Other Attach Plate
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W13-01L/R
For the oval hole in the other attach plate I decided to drill a single hole and then cut the entire oval using a coping saw. This seemed to work quite well. I did some sanding with the drum sander. When I overlayed the parts I discovered that the two ovals were not the same size. After some measuring I discovered that I had measure one of the holes wrong. I was too small. Whew! Making a hole bigger is easier than making it smaller. After marking the correct hole size is used a round file to open up the hole.

Finishing The Attach Plates
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W13-01L/R
I finished the attach plates today by drilling the 3/16 inch holes at the end of the plate and then sanding and scotch briteing the parts.

Drive Horn Template
Type of Work: Construction
Category: Rudder
Manual Reference: SNX-T13-03
The drive horn shown in the plans has no dimensions but is drawn full scale. I decided that the quickest way to make this part was to start with a template. I used a piece of drafting paper to trace the drive horn from the plans. I then glued the drafting paper to a piece of bristol board and cut it out. This provided a rigid template that I could trace for the final shape on the aluminum.

I traced the shape onto the aluminum and used the band saw to cut out the rough shape. Next, I started the sanding.

More Work on the Drive Horn
Type of Work: Construction
Category: Rudder
Manual Reference: SNX-T13-03
I continued working on the drive horn today. I center punched and drilled all of the pilot holes, completed the sanding and used scotch brite to clean up the part. I filed the bevel on the one edge as indicated. This appears to provide some relief when the horn is riveted to one of the ribs for the rudder.

With all of this work completed I started to setup for bending the drive horn.

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.

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.

Travel Stop Plate
Type of Work: Construction
Category: Landing Gear
Manual Reference: SNX-L02-04
I made the travel stop plate. This was the last part from the 3/16" aluminum sheet.

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.

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.

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

Flap Drive Plate
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W06-04
Measured and marked the part out on the aluminum. Cut it out on the bandsaw then filed the part to finished size. Marked the holes for drilling.

Flap Drive Plate
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W06-04
Drilled the holes and cleaned up with scotch brite.

Bell Crank Plate
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W21-11
I completed the bell crank plate. Layed it out, cut, filed and sanded it, then drilled the pilot holes

Doubler
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W13-04
Marked and cut out both doublers on the bandsaw. I dilled a starter hole and used a copping saw to cut out the large hole in the doubler. Next I used a sanding drum in the drill to finish the hole. I filled and sanded the edges then marked and drilled the pilot holes.

Doubler
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W13-04
I added the rad to the bottom edge of the doublers. I forgot these when I originally made the parts so I had to go back.

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.

Cable Attach Bracket
Type of Work: Construction
Category: Landing Gear
Manual Reference: SNX-P15-16
Another, cut, fille, sand, mark and drill.

Spacer
Type of Work: Construction
Category: Vertical Stabilizer
Manual Reference: T09-03
Cut, file and sand to complete this part.

Radius Block
Type of Work: Construction
Category: Wings
Manual Reference: SNX-13-03
These were a bit fiddley(sp). I ripped a strip of aluminum to 1/2" then filed one edge flat and added the radius to the other long edge. Next I setup my fence in the bandsaw to 5/8" and cut out all of the blocks. Finally, I sanded the fresh cut edges. I think I have all of the 1/8" parts complete except for the inner spar webs.

Main Spar Center Web
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W10-03
I started the layout of the main spar center web. To begin with I cleaned up the top and bottom edges with the vixen file and sanded until I had two straight edges that I could work from.

Main Spar Center Web
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W10-03
Today I finished the layout of the first web, cut it out and then did the same with the second one.

Main Spar Center Web
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W10-03
I finished up the center webs today. I used a whole saw to cut out the 1-1/2" hole but I actually used a 1-1/4" hole saw then opened up the hole to 1-1/2" with a sanding drum in the drill press. I did not drill all of the pilot holes as I will wait until I create one of the other spar webs to use as a template

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

Aileron Drive Plates
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W04-04
These were two simple parts also. I layed these out directly from measurements onto the aluminum. Cut the pieces to size on the band saw and rounded the tip using the bench sander. Next I filed and sand the edges. I marked all of the pilot holes and setup a fence on the drill press for 1/4" as this is the edge distance for the holes. Next, I drilled all of the holes. I left the 3/16" hole for later but pilot drilled it 3/32" for now. I finished the parts using scotch brite.

Counter Balance Plates
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W07-07
I started each of the four plates by cutting a length of 0.090 aluminum from the strips I had previously ripped on the band saw. Next, I filed the two long edges to get 3-3/8" inches. With this done I simply measured and marked the remaining cuts. These were then cut on the band saw. I filed and sanded the edges to get the final outside shape. Once all four were ready I started to layout the 3/32" pilot holes for the rivets. This was straight forward and I drilled most of the holes in the drill press.

Work on W04-07
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W04-07
Finished making W04-07

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.

Splice Plates
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W12-04
I cut out the splic plates and marked the holes.

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.

Gascolator Mtg Bracket
Type of Work: Construction
Category: Firewall Forward
Manual Reference: SNX-G01-07L/R
I cut out one of the brackets.

Gascolator Mtg Bracket
Type of Work: Construction
Category: Firewall Forward
Manual Reference: SNX-G01-07L/R
I cout out the second bracket and finished both.

Push Rod Boot Plate
Type of Work: Construction
Category: Landing Gear
Manual Reference: SNX-L02-06
I made the push rod boot plate.

Nose Pant Attach Brackets
Type of Work: Construction
Category: Landing Gear
Manual Reference: SNX-L06-14
I made the nose pant attach brackets

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

Welding Preperation
Type of Work: Planning / Misc
Category: Planning and Paperwork
Manual Reference: None
In preperation for welding I have purchase some welding rod and am in the process of getting some new tips for our Oxy-Acetylene torch at work. I also need to order some new band saw blades to cut the 4130 steel. Hopefully, I'll get these in about a weeks time and can finally get back at building.

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.

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.

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.

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.

Finishing Up Rudder
Type of Work: Construction
Category: Rudder
Manual Reference:
It's been a while since I made an entry in my builders log. Work has been very slow but I am trying to get back at things and get back to recording my work. Today I was working on my rudder. I spent time deburring the ribs for inside the rudder. I found that a tongue depressor wrapped in sand paper works well to break of the burr on the inside of the flanges. After getting everything deburred, I began the riveting process. I started by riveting in the center rib then the hinge. Next, I reveted the rudder drive horn assembly. I left the drive horn assembly and the top rib off so that this area could be inspected as part of my precover inspection.

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.

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.

1. Start with a piece of drafting paper. It is see through and makes good tracing paper.
2. 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.
3. 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.
4. 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.

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.

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.

Wing Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W10
Working on layout of wing spar.

Wing Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W10-01
I spent a fair bit of time today finishing the layout of the wing spar. Once all the layout was complete I setup my drill press and drilled the pilot holes. I still need to put in the large 1-1/2" hole but the rest of the holes are complete. My next stop will be to clamp it to the blank for the other side of the wing and use it as a template to get all of the holes drilled in that spar.

Wing Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W01
Spent more time today getting the other wing spar blank made to size. I'm now ready to setup and start using the first spar as a template to drill the second spar.

Wing Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W10
I worked on drilling the second wing spar using the first as a template. This was fairly easy but time consuming. Still, it was easier than all of the layout work that went into the first spar.

Making clips from angle stock
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W21-09
I finished trimming the leg of the angle to the correct lengths. Search for the hardware required and discovered I need to order some phenolic.

Aileron Bellcrank Installation
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W21
I picked up my phenolic at aircraft spruce in Brantford this morning. Now I can complete the bellcrank installation. I had previously traced one of the phenolic spacers and I transferred this to the phenolic then cut it out on the bandsaw. It really stinks. Probably not to good to breath. I sanded the spacer on my bench sander. Next I marked the hole for the AN3 bolt that holds the clevis assembly together. After drilling the 3/16 hole for the bolt I then colecoed the clevis to a piece of hardwood to keep the parts in alignment while drilling the rest of the holes. Before drilling the 7/16 hole for the bushing I decided to drill a trial hole in a piece of 1/8 stock. I don\'t have a reamer so I wanted to be sure that the bushings would fit okay in a drilled hole. The drilling process didn\'t work very well. I managed to get to 27/64 before I ran into problems. I started the same process with the clevis and drilled up to 1/4 before stopping for this session

Aileron Bellcrank
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W21
I continued to increase the size of the bushing whole in the bell crank using progressively larger drills. When I got to the last one it jammed and stopped the drill. Now I finished the job with sandpaper on a dowel. A reamer would be nice about now. Using sand paper and a small round file worked okay. I managed to get the holes opened up so that the bushings would fit. Next I assembled the bellcrank in the clevis. I had to dig out my copy of AC43.13 to look up the correct torque specs and the correct method to secure the cotter pin. I seems to work pretty good. Next, on to the second assembly. I almost completed the second assembly. I just need to insert some shims to free up the rotation.

Aileron Bellcrank Installation
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W21
Today I drilled up the holes in the #9 ribs to #30 for the mounting of the bellcranks.

Rear Spar Assembly
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W12
.Cut out large rectangular hole in the spar tip, -03L/R. Started to layout spars with all of the fittings in preparation for drilling. Currently I\'m puzzled by the two rivets called out between the bolts at the inboard end of each spar. I\'ll have to take a look at the group postings on yahoo.

Rear Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W12
Drilled the pilot holes for the ribs. Started to prepare for assembly of the left rear spar. Drilled the rib holes in the attach plate. Completed the pilot holes in the attach plate. Started installing the doubler.

Drilling holes in Rear Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W12
Completed drilling of pilot holes in the left hand rear spar. Started drilling pilot holes in the right hand rear spar.

Drilling pilot holes in Right Hand Rear Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W12
Completed pilot holes in the right hand rear spar. Clean up clearance holes for control rods. Started reviewing plans for ailerons and flaps.

Flap Drive Ribs
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W06-05
Riveted one of the drive ribs. Layed out the position of the drive plate on the second rib. Drilled pilot holes through drive plate into drive rib. Completed drill and riveted the second flap drive rib. Started laying out rib locations on right hand flap skin.

Flap
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W05-01
Continued laying out the holes in the flap skins. Completed hole layout on right hand flap skin. Drilled pilot holes in the top and bottom of the flap skin.

Drilling holes in right hand flap assembly
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W05-01
Tonight I worked on completing the pilot holes in the flap assembly. Next I started to transfer the holes through to the ribs. I worked on the most inboard rib first.

Drilling Flap Skins and Ribs
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W05
Continued transferring the holes in the flap skin to the ribs. I\'m supporting the flap skin on a couple of 2x6s to provide room for the clecos to protrude down. The best sequence seems to be to insert the rib, clamp it in place using a spring clamp and then drill the holes in the narrowest (front facing) edge. After I get the first four holes drilled in the front edge I switch to either the top and the bottom. I\'m not drilling the holes for the hinge at this time although I have marked the hole position at each rib. I complete all of the #40 holes for the ribs. Next time I\'ll start on the left flap.

Flaps
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W05/06
I started today by making up the hinge for the right hand flap I was drilling yesterday. I marked and drilled all of the pilot holes in the hinge. I discovered that I made a mistake when I placed the ribs inside the flaps and they are off by 1/4 of an inch so I needed to adjust a couple of holes in the hinge to line up with the ribs. I left these for later. After drilling the pilot holes I started working on attaching the hinge to the flaps by transfering the pilot holes in the hinge to the flap. Complete the holes between the inboard rib and the next one out. I continued drilling the pilot holes for the hinge after dinner and managed to get the holes 2/3 complete.

Drilling the Flap Skins
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W05/06
Tonight I am continuing with transferring the pilot holes in the hinge to the flap skin. After completing the hinge holes I cut the mating hinge piece to length

Upsizing holes in Right Flap
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W05/06
Today I started increasing the size of the holes in the right hand flap from #40 to #30. I used my soldering iron to cut away the protective film around all of the rivet holes leaving the rest of the skin protected. It worked well. Next I started to deburr the holes. I completed the first pass on deburring the skin moved on to the ribs.

Prep and Assembly of Right Flap and Start on Left Flap
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W05/06
Today I started by deburring all of the edges on the flap skin. Next I pulled the rivets on two sides leaving a flap open for inspection prior to closing. After completing the right flap I started to layout the holes in the left flap. I matched the same mistake I made on the right side in order to ensure the two flaps look the same. After marking all the holes I drilled all the #40 pilot holes through the skin and then I started to install the ribs and complete the pilot holes into the ribs.

Left Hand Flap
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W05/06
I started by getting the pilot holes layed out on the hinge. Next, I drilled the pilot holes in the hinge and then transferred the holes to the flap skin. The next step was to enlarge the holes to #30. Next time I\'ll take everything apart and start deburring.

Deburring and Riveting Left Flap
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W05/06
After removing all of the clecos and labeling the inner ribs I proceeded to deburr the ribs. The outside was easy using my swivel deburring tool but the inside of the flanges was more difficult. I used some 220 grit Al oxide sandpaper on a popsicle stick to break the burrs off from the edges of the rivet holes. Next I used a scotchbrite pad so finish the ribs. With the ribs completed I proceeded to use a block of wood to hold the flap skin open to provide access to the inside. Again, I used the w220 grit Al oxide sandpaper on the popsicle stick to break the burrs off the edges of the rivet holes. With the skin deburred I reassemble the flap using clecos and started the riveting. Again, I left the flap such that it could be opened for inspection.

Deburring the hinges
Type of Work: Construction
Category: Wings
Manual Reference: Flaps
I deburred the hinges and then wrapped up the flaps for storage until I can get them inspected. Now on to the Ailerons.

Aileron Ribs
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W04
Time to start laying out the 6 Aileron Ribs that I need. After tracing out the ribs, I cut them out with the Malco snips. Next I marked and drilled the holes for the radii at the flanges. Finally, I trimmed the ribs to size.

Fabricating Aileron Ribs
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W04-02/03
I started the work today by cleaning up the rib blanks I cut out earlier. I used my bench sander as well as a sanding block and files to get all of the rib blanks to the same size. (Or as close as I could get) After making all of the blanks the same size I set up my bending brake and formed all of the flanges. Three of the ribs needed to be made left hand and three right hand. After forming the first three ribs I had to transfer the bend lines to the back side of the remaining blanks so that they could be formed in the opposite direction. I then formed all of the flanges. Next, I used my scotchbrite to clean up all of the ribs.

Making Molds for Aileron Counterweights
Type of Work: Tooling
Category: Wings
Manual Reference: SNX-W04
I used some hardwood to create the mold for the counterweights. The wood was only 3/4 of an inch thick so I doubled up the thickness. I screwed the two blocks together then I cut out the form using a jig saw. Next I used a third piece for the bottom of the mold. I drilled through all three pieces and bolted them together. I figured it would be easy to remove the bottom after the lead hardens and I would be able to tap the weight out.

Making Aileron Counter Weights
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W04
I purchased an inexpensive pot and proceeded to melt my lead divers weights on a camp stove. It seemed to take quite a while for the melting to begin but once it started it proceeded fairly quickly. Once I had about 1/2 of one 8 lb weight melted I decided to try pouring. Pouring the lead into the mold was pretty uneventful. There seemed to be a lot of bubbling going on. I\'ll have to see what the results look like after I get the lead out of the mold. The first weight looked great out of the mold. The second one was not quite so nice. I used my plumbing torch to melt some additional lead and fill in the voids.

Counterbalance Assembly
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W04
Today I started to drill the holes through the lead weights. I started with a #30 bit so that I could keep the holes lined up with the aluminum counterbalance plates. After; the #30 I moved up to the finished size of 3/16 inches. I used a pecking action and some candle wax as a lubricant and had no problems.

Second Counter Weight Assembly
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W04
I started by using the aluminum counter balance plates to drill #40 pilots for the the through holes in the counter weights. After marking all the holes I continued using a #30 drill in the drill press.

Aileron Counterbalance Assembly
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W04
I continued drilling the #30 holes through the lead weights today. Next I enlarged the holes to 3/16.

Channel Assembly
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W04-09
I need to make two channel assemblies, one for each counter balance assembly. I started by finding my Z02-03 angle stock. Next I cut the 4 pieces to length and started to trim them to width.

Channel and Counterbalance Assembly
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W04
Today I complete the trimming of the channels. I drilled the rivet holes in both angles to make up the channel assembly then I started on the counterbalance assemblies. I measured and drilled the first pilot holes in the aileron ribs for the counterbalance plates. Next I realized that I did not have enough ribs and have proceeded to cut out two more.

More Aileron Construction
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W03/04
I completed finishing and forming the last two aileron ribs. Next I started to layout the aileron skins. I have to make sure to measure twice and cut once. One of the tough dimensions is the 2-19/32. I decided that that dimension should be at the start of the radius on the end of the aileron. I then sighted across the aileron to complete the curve around the edge radius.

Ailerons
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W03-03
I completed all of the pilot holes (#40) in the counterbalance assemblies and moved on to the drive rib assemblies. I also drilled all of the pilot holes in these assemblies. Next, went back to work on the aileron skin and cut out the notch for the drive rib assembly. After cutting out the notch I went back to work on the counter balance assemblies. I enlarged all of the holes to #30 then I proceeded to install the small channels that I made earlier. I would like to put the rivets in the channels from the outside but I don\'t know if there will be enough room. I may try a rivet or two to see if there is enough room for the rivets. A test of the rivets didn\'t work. I guess it\'s best just to follow the plans. I disassembled one of the counterbalance assemblies and deburred one half. Next, I riveted the half together. Tonight, I finished riveting the counter balance assemblies and the drive ribs.

Aileron Skins
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W04-01
I double checked my measurements then cut out the notch for the counterweight. Next I cut the end of the aileron skin. My tip ribs don\'t seem to fit right but this seems to be a common problem. I\'ll continue with the second skin then work on the tip ribs. I\'ll probably have to make new ones. I hope I don\'t have to build the whole plane twice 8^D. I completed about 90% of the layout for the second aileron skin.

Aileron Skins
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W04
Started to cut out the Aileron Skin

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.

Aileron Tip Rib
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W04
Tonight I cut out and formed a new aileron tip rib based on the new drawing I created using my 3D model of the aileron skin. Wow, it fits great. I still need to do a bit of work on trimming the skin but the rib seems to fit great.

Aileron Tip Rib
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W04-10
Aileron Rib 1 - Trace and cut out blank 2 - Drill hole for radius before notching 3 - Trim notch and then file edges to side. 4 - Form angles Aileron Skin 1 - Trim longest cut edge to exact size. 2 - Clean up front edge (shortest edge) 3 - File angle at trailing edge to match tip rib. 4 - Trim the lower edge of the aileron skin to meet the front and back. Clean up the edges and check the fit of the tip rib. After completing the tip rib and aileron skin I started to layout the rivet holes. I started do drill the holes for the counterbalance ribs but I discovered that I need a long drill bit.

Aileron Assembly
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W03
I continue to work on the aileron assembly, drilling pilot holes and laying out the holes on the skin. I completed all of the pilot holes in the left aileron skin and clecoed it together. Next I cleaned up and move on to the right aileron skin. I finished all the pilot holes in this skin as well. I should say all the pilot holes except for the hinge on both ailerons. That\'ll be for another day.

Aileron Assembly
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W03
Tonight I removed the clecos so that I could check the overlap of the skin before drilling the hinge. I have found in the past that one of the control surface skins did not have the correct overlap and I did not end up with the correct edge distance. This one seems pretty close. I think I will move the holes about 1/64th closer to the edge of the hinge to provide the best edge distance for both the hinge and the skin.

Aileron Hinge
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W04-06
Drilled the pilot holes in one hinge and then started to transfer the holes to the small flange on the skin.

Ailerons
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W03
Tonight I worked at completing the pilot holes for the hinge in the aileron skin. I pretty much completed all of the pilot holes. I discovered there was one left when I took apart the aileron. My next step will be to enlarger all the holes to #30.

Ailerons
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W03
Re-drilling pilot holes up to #30

Deburring Right Aileron & Completeing Left Aileron
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W03
I completed deburring the right hand aileron and moved back to the left aileron. The first step was to mark the small flange so that I could determine what overlap I would have. I looks like I\'m shy about 1/64th from the 1/4 inch edge distance that I would like to achieve. Next I marked the hinge and drilled most of the the pilot holes. I left out the one at the middle rib and the ones at the counterbalance ribs. I\'ll mark and drill these while transferring the holes from the hinge to the skin. I transferred all of the holes in the hinge to the skin. Next, I marked and added the holes through the each of the ribs.

Left Aileron
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W03
I completed up drilling to #30. Now I need to deburr all of the holes. With all the holes deburred and the ailerons clecoed together I think it\'s time for my first inspection by the MD-RA.

Deburring Main Spar Webs
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W10

Riveting Ailerons
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W03
After having my MD-RA inspection yesterday I was able to start closing up all of the components that I have made so far. Today I started with the ailerons.

Completing Riveting on the Rudder
Type of Work: Construction
Category: Rudder
Manual Reference: SNX-T08
A couple of rivets at the lower rib needed to be pulled by hand as they seemed to interfere with the rivets holding the control horn. By using a hand puller I was able to ensure that the head was seated properly as I slowly pulled the rivets.

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.

Riveting the Elevator
Type of Work: Construction
Category: Elevator
Manual Reference: SNX-T02

Finishing the Rivets on the Vertical Stabilizer
Type of Work: Construction
Category: Horizontal Stabilizer
Manual Reference: SNX-T08

Preparing Completed Parts for Storage
Type of Work: Planning / Misc
Category: Planning and Paperwork
Manual Reference:

Cleaning Up the Spar Caps
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W09

Cleaning Up the Spar Caps
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W09-02L
I worked on the left hand lower spar cap. I continued to work at removing the left over flange that had been machined off. I know this is not really required but it makes the tie down fitting fit better and looks nice.

Lower Left Wing Spar Cap
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W009-L02
Tonight I continued on my clean up of the spar cap. I finished the work on the small 1/16 inch flange.

Continued Cleanup of the Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W09
Today I am continuing with the cleanup of the wing spars. I'm using a small half sheet sander, my sanding block and scotch brite. I completed the two lower spar caps. Next I'll work on the upper spar caps. These I won't be as fussy about the machined of flange. The plans allow it to be proud by up to one sixteenth so I'll just focus on cleaning up the machined edges and getting rid of the scratches.

Cleaning Up The Upper Wing Spar Caps
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W09
Wow, I completed one of the upper wing spar caps. They are a a lot of work. It takes a fair bit of elbow grease to get all of the small scratches out. Tomorrow I'll work on the last spar cap. Then I'll be ready to work on the spars themselves.

Cleaning Up The Last Spar Cap
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W09
I completed the cleanup of the final spar cap. Now on to assembling the spars.

Main Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I worked at getting the left hand spar assembled. I fit the web and drilled a bunch of the pilot holes so that I could cleco the spar together.

Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I continued to drill the pilot holes in the left wing spar.

Drilling Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Today I continued to drill the pilot holes in the left wing spar.

Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I started by studying the plans to be sure that I understood the stack of spar webs. Next I realized that I could use the 0.090 thick spar webs to layout and drill all of the pilot holes in the various angles that go at the inboard edge of the spar. My plan is to open up the alignment holes to 3/16" in order to ensure that the root wing attache assemblies and end wing wing attach assemblies can be lined up using the current 3/16" hole that is in the attach blocks. To get to this point I overlapped the two 0.090 web spars and clecoed them using the wing attach holes and the center alignment holes. Next I drilled out the remaining alignment holes to #30. My intent here was to ensure the the attach holes were aligned (using clecos) and then end up with exceptional alignment of the intermediate holes by up drilling both at the same time. Next I inserted copper clecos in the intermediate holes and proceeded to up drill each of the remain three holes to #30 one at a time. After drilling to #30 I moved on to 3/16 for the wing attach points only. This will serve to align the wing attach blocks. Next I used the 090 spar web to pilot drill the first of the angles at the inboard end.

Wing Saprs
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08

Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Today I completed all of the pilot holes in the left wing spar and moved on to work on the right wing spar. I setup the right spar and proceeded to drill all of the pilot holes at each of the rib stations.

Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I continued drilling the pilot holes in the right wing spar today. I completed all of the pilot holes in the right hand wing spar. The next step will be to mark all of the holes for countersinking and then to experiment with the countersink. I'll complete all of the bolted connections first and then move on to the rivets.

Up Drilling Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Today I started up drill the wing spars to #30.

Up Drilling Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Continued work on the right hand spar up drilling to #30.

Up Drilling Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08

Counter Sinking Wing Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I worked on counter sinking the upper right hand spar cap. I completed all the counter sinks but I have a few that I need to go back and enlarge slightly.

Counter Sinking the Spar Web
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I started by marking all of the holes that need to be counter sunk in the 1/8 web. Next I setup the microstop in the drill press and proceeded to drill the counter sinks. I started drilling fairly slowly but I discovered that it was better to drill quick.

Up Drilling Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Tonight I'm working on up drilling the wing spars to #21.

Updrilling Spar to #21
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08

Up drilling to #21
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Today I continued up drilling to both #21 and 3/16". It seems to be taking me a long time. I'm sure if I just drilled by hand it would go quicker but I like the idea of using the drill press to get nice square holes. The holes are actually round it's just that they are at 90 degrees to the surface I am drilling through.

Up Drilling Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Today I completed all of the up drilling at the root end of the spar and all of the holes along the top spar cap. I just have the holes through the web along the lower edge of the spar to complete.

Up Drilling Wing Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I looks like one more night and I should have all of the drilling of the spar finished.

Up Drilling Wing Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Tonight I completed the up drilling on the right wing spar. Now I need to debur, dimple, alodine and rivet.

Right Main Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I started with a bit of cleanup today and then I moved on to completing the countersinking for the counter sunk screws. After setting up my microstop I completed the countersinking of the 1/8 inch center web and the single hole in the top spar cap. With all of the drilling and countersinking complete I moved on to deburring.

Deburring Right Wing Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
After deburring the main spar web I proceeded with the dimpling. I used my new squeezer for most of the dimples and then used a rivet, bolt and hammer to complete the last few. Next I continued the cleanup of the other web sections and then moved on to the spar caps.

Drilling Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Today I started by cleaning up the last few angles for the right spar, then I swap the two spars on the bench so that I can start up drilling the left spar. I setup the drill press with a new #30 drill bit and proceeded to open up all of the holes at the root end of the spar. I completed about 1/2 of the holes at the root end where the various web doublers are located.

Up Drilling Left Wing Spar to #30
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I completed all of the up drilling to #30 at the root end of the spar. Now I can take it apart and complete all of the rivet countersinks. I completed the counter sinking of all of the rivet holes and then proceeded to start up drilling to #21.

Up Drilling the Left Main Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08

Drilling The Main Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I finished up drilling the in board end of the left main spar. This is the portion with all of the web doublers. The next step will be to remove all of the doublers and then to up drill the remainder of the spar.

Updrilling #40 to #21 on Outboard end Of Left Main Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I completed all of the up drilling today. Next I will take the spar apart and start the cleanup with scotch brite.

Preping Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Today I continued to clean, prep, alodine and paint the components for the left main spar. I finished painting all of the small parts and got the larger web doublers alodined. Next will be the spar caps and the main spar web. I need a warm day that I can work on these outside.

Riveting Left Main Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08

Riveting
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08

Riveting the Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I started today by working on re-dimpling the top edge of the W10-02 web doubler. I found that the original dimples did not fit well into the spar cap so I used a rivet to reset the dimple before final riveting to ensure a good fit. After reseting the dimples I continued with the flush rivets. I made up a new bolt for setting the rivets using a 3/8" bolt for the rivets between the top angle and the spar cap.

Riveting Left Main Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08

Riveting Left Wing Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08

Riveting Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Today I finished all of the rivets in the Left Main Spar except for the ones required for the tip web.

Preparing Right Spar For Riveting
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Tonight I reset all of the dimples in the right main spar web and cleaned up the web using scotchbrite.

Alodineing and Painting Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Today I alodine coated all of the small parts for the right main spar and then painted all of the parts with zinc chromate primer. (Canadian Tire Spray Cans) Now I need to wait a few days for the paint to harden well and I can start riveting the right main spar.

Making Web Spacer and Centre Spacer
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W14
I used a bunch of scrap .125 aluminum to make twenty centre spacers (SNX-W14-02). This was a bit time consuming but time is free and I had the scrap. After making up the centre spacers I clecoed the right main spar together.

Riveting Right Main Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I riveted the lower angle and secured all but one of the -7 bolts. It turns out I am short one bolt. I'll have to order a few more. I also fastened the end wing attach assembly to the inboard end of the spar. I left one of the AN4 bolts out of the block to allow bucking of the nearby rivet.

Riveting Right Main Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Continued installing flush rivets.

More Riveting
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I finished all of the flush rivets in the right main spar.

Riveting the Right Main Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I finished all of the solid rivets in the W10-05 web doubler.

Continued Riveting of the Right Main Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I completed all of the rivets in the inboard end web doublers. I finished about half of the remaining rivets today.

Riveting Right Main Wing Spar
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I finished all of the rivets except for the tip web assembly.

Mating Left and Right Wing Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
I completed drilling the 3/16 inch hole through each of the wing attach points using the 3/16 hole in the attach blocks as adrill bushing. I had not up drilled the spar web earlier. After up drilling the attach points I married the spars for the first time. All of the holes lined up very well. I up drilled the three remaining holes to #30 then to #21. Finally I up drilled the center hole to 3/16 of an inch. I decide to take things apart at this point to check things out. All looked good so I decided to up drill the remaining two holes to 3/16.

Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08

Finising Up The Spars
Type of Work: Construction
Category: Wings
Manual Reference: SNX-W08
Today I worked on the spars again. I was cleaning up the minor scratches from assembly, torquing all of the fasteners, and generally getting things ready for the assembly of the wings. I completed all of the last riveting and assembly. The only thing left is the final up drilling to 1/4 inch which I need to do when the weather will allow me to extend the spars outside the garage again.