Builder Log for ...

Sonex 963

Building a Dream!

September 12, 2006 ...   I fabricated these brackets today and had to re-make one bracket. After cutting and fabricating the aluminum angle material to the precise dimensions stated in the drawings, I decided to go ahead and drill the 6 holes specified. Everything turned out perfect until I went to make the 10 degree bend in the bracket. At that point the bracket proceeded to bend on the side with the holes (indicated by the arrow on the photo) rather than the solid side. I re-made the bracket and decided to wait on the holes until it was time to assemble the brackets on the main spar assembly. Without the holes, setting the 10 degree angle worked out perfectly.

September 18, 2006 ...  I finished  fabricating, drilling and deburring the internal parts for the horizontal stabilizer. They are ready for Alumi-Prep, and Alodine 1201. I took a few minutes to set-up the parts in a loose layout (without Clecos) to get a "visual" of how everything will go. So far, it all looks great!

Double-click on photos to enlarge.

Photo Courtesy of Sonex Aircraft, LLC

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September 22, 2006 ...  Prior to assembling the Horizontal Stabilizer forward spar, I drew some reference lines on my bench top which helped me layout the forward spar. Several forward spar dimensions on the drawings are with reference to the stabilizer centerline. So, I marked  that on my bench top (indicated by yellow arrow), and also on the forward spar. I attached a block to my bench top which allowed me to firmly secure the spar assembly during the fit and assembly process. You will also notice that I am laying out the stabilizer bottom side up. This is necessary to properly assemble the forward spar channel parts in accordance with the drawings.