| 1.1. Sonex - construction |
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cut aluminium angle kit to lengths
cut angle
cut angle
cut 1" angle
F10-06, F14-11LR, F22-06
W11-10LR, W11-09x2, W11-11x2
W11-05x1, W11-08x2
W11-07, tablesaw test
F03-05L&R, F03-06L&R
F14-08R&L (took a while!)
F14-07R&L
F14-02R&L, L05-07, D02-14
D02-14, F10-19, F10-20, F14-13R&L
F14-12R&L (seat belt attach)
F15-01R&L engine mount attach brackets
F15-01R&L engine mount attach brackets
F15-02R&L engine mount attach brackets
F15-04R&L rudder pedal mount angles
F15-07R&L, F15-12R&L flap drive mounts
F16-09 cross tie
F16-04 support angle
F16-04 support angle
F10-05R&L seat belt attach brackets
F16-06R&L vertical angles
F22-05 aft angle
F23-03/04 tailwheel mounts
F23-03/04 tailwheel mounts
T03-03 horiz stab attach angles (2)
T12-05 vertical stab attach angle
W13-02R root rib attach angle
W13-02L root rib attach angle
W21-03/04 right aileron bellcrank pivot angles
T03-02 tailplane spar fitting
T03-02 tailplane spar fitting
W21-03/04/06/07 aileron pivot angles
W21-03/04/06/07 aileron pivot angles
channel inventory & preliminary work
channel cut list check
cut all channel material to length
horizontal stabiliser plans review
0.060 sheet parts, T06-05 (1 + 1 scrapped)
0.060 sheet parts, T06-05 (2)
0.060 sheet cut layout
0.060 sheet parts T12-06, 09
0.060 sheet parts, W12-04(2), W11-04(2), G01-07RL, F15-05, W23-05
horizontal stabiliser parts layout
T03-04 HS main spar channel (2)
T03-01 HS main spar assy
T03-01 HS main spar assy
F15-05 (x2)
T03-06 HS forward spar channel (x2)
T03-05 HS forward spar assy
T03-05 HS forward spar assy
T03-05 HS forward spar assy
T02-02 HS substructure assy
T02-02 HS substructure assy (T04-01 ribs)
T04-02L
T04-02R
T04-03L&R
T04-04L&R
T02-02 substructure assy (drill ribs into position)
T02-02 substructure assy (redrill to #30)
T02-02 substructure assy (T04-06 LE ribs)
T02-02 assy (T05-01L&R skin attach)
T02-02 assy (T05-01L&R skin attach)
T02-02 assy (T05-01L&R skin attach)
T02-02 assy (T06-04 hinges)
T02-02 assy (T06-04 hinges)
T06-02 elevator root assy
T06-02 elevator root assy (don't drill holes in 4130 steel with high-speed air-drill!)
T06-02 elevator root assy (don't drill holes in 4130 steel with high-speed air-drill!)
T07-01L&R elevator skins (trailing edge to fence; cut and pull
T02-03 elevator assy
T07-08 elevator hinges (drill pilot holes)
T02-03 LH elevator (drill hinge & ribs in place)
T02-03 RH elevator (drill hinge & ribs in place)
T02-03 RH elevator (drill hinge & ribs in place)
T02-03 elevator assy (install T06-02 root assy)
T06-02 elevator root assy (check dimensions - seems too big) - elevator horn is correct; my mistake was cutting the inboard end of the elevator skins with the lower surface laying flat instead of the upper surface. This has thrown the cut angle out around both the vertical and longitudonal axis. Luckily another result is that the skins have ended up too long, so I should be able to re-trim them correctly.
T07-01R&L elevator skins (retrim inboard end to correct angle)
T02-02 assy (redrill skin holes to #30)
T02-02 assy (redrill skin holes to #30)
T02-03 elevator assy (fit to HS & install root assy)
T02-03 elevator assy (fit to HS & install root assy)
T02-02 HS assy (disassemble for final part cleanup & alodining)
T02-03 elevator assy (redrill to #30)
T08-01 vertical stabiliser review & parts inventory
T08-01 vertical stabiliser familiarisation (confusion about what kit stock to make T09-03 (and other thick sheet parts) from)
T09-03 temporary spacer (made from spare 2.5x2.5x1/8 angle)
T12-08 VS forward spar channel
T09-02 VS fwd spar assy
T12-10 clip
T09-02 VS fwd spar assy
T12-03 VS upper spar channel
T12-01 VS main spar aft strap (redrill laser holes)
T09-01 VS main spar assy
T09-01 VS main spar assy
T09-01 VS main spar assy (bolt holes)
T09-01 VS main spar assy (bolt holes)
tidy up work area
T08-01 vertical stabiliser layout
T08-01 vertical stabiliser frame
T10-02 VS rib
T10-03 VS rib
T10-04 VS tip rib
T08-01 VS frame (pilot drill ribs etc)
T08-01 VS frame (pilot drill ribs etc)
T08-01 VS frame (T10-05 LE rib)
T08-01 VS frame (redrill to #30)
T08-01 skin attach
T08-01 skin attach
T08-01 skin attach
pondering mistake in T10-05 LE rib position (forgot to install T12-07 before drilling rib)
T08-01 redrill skin to #30
T10-06 upper hinge (drill into place)
T08-01 redrill skin to #30
clean up and rudder assembly review
T13-01 rudder skin
T13-03 rudder drive horn (drill holes)
T13-03 rudder drive horn (bend + chamfer)
T13-02 rudder drive horn assy (+ T13-06 clip)
T13-07 rudder hinge
T08-02 rudder assembly (cleco hinge)
T08-02 rudder assy
T08-02 rudder assy
T14-03 vertical tail tip (need dremel cut-off wheel)
T14-03 vertical tail tip
disassemble VS & rudder
T12-04 (drill 1" hole)
T12-04 (drill 1" hole)
AN3 (3/16) bolt hole problem (holes are too tight?)
debur tail parts
debur tail parts
debur tail parts
debur tail parts
debur tail parts
organise wing spar parts
0.032 sheet parts layout
W10-07 x 2
organise wing spar parts
W08-01R&L main wing spar assemblies
wooden spar support blocks
wooden spar support blocks
W08-01L main wing spar (fit main web)
W08-01L main wing spar (fit main web)
W08-01L main wing spar (drill holes #40)
W08-01L main wing spar (drill holes #40)
W08-01R main wing spar (drill holes #40)
W08-01R main wing spar (drill holes #40)
W08-01R main wing spar (redrill to #30)
W08-01L main wing spar (redrill to #30)
W08-01L main wing spar (redrill to #30)
organise wing spar angle parts
W11-01 lower spar angles (2)
W11-03 wing attach blocks (1/4)
W11-03 wing attach blocks (2,3,4/4)
W11-02 end wing attach assembly (1/2)
W11-02 end wing attach assembly (2/2)
W11-06 root wing attach assembly (1/2)
W11-06 root wing attach assembly (2/2)
clean up work area
root angle layout / pilot drill (right spar)
root angle layout / pilot drill (right spar)
root angle layout / pilot drill (left spar)
W08-01R main spar assembly (prepare for final drilling)
W08-01L main spar assembly (prepare for final drilling)
W08-01L main spar assembly (prepare for final drilling)
W08-01L main spar assembly (final drill to #21)
W08-01L main spar assembly (final drill to #21)
W08-01L main spar assembly (final drill to #21)
W08-01L main spar assembly (drill 3/16 holes x 18)
W08-01R main spar assembly (final drill to #21)
W08-01R main spar assembly (final drill to #21)
W08-01R main spar assembly (final drill to #21)
W08-01R main spar assembly (drill 3/16 holes x 18)
clean up work area
W10-04R&L tip webs
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