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Builder Log for ...
Sonex 963
Building a Dream!
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Page 4
Photo Courtesy of Sonex Aircraft, LLC
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March 27, 2007 ...  I spent a few hours in the shop today getting a few more parts fabricated for the wings. My goal is to first fabricate, pre-drill, and debur all of the parts needed to build the wings prior to wing assembly. Today, I started the aileron bellcrank brackets; deburred the aileron bellcranks (provided in the airframe kit), drew in the cuts I need to make on the bell crank brackets, and chamfered the wing root attach blocks. My wife bought me a 10 inch disk sander for my birthday which worked extremely well for the chamfers, and promises to be a great help on other parts in the future.
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April 5, 2007 ...  Sometimes an hour here and an hour there is all I can get in the shop. But those hours add up to considerable progress over time. Today, I finished drilling the right aileron bellcrank  pivot bracket, alodined the bellcrank and brackets, and fabricated the 1/4 inch phenolic spacer that goes between the brackets.  I then pressed in the bronze bushings and temporarily assembled everything (less the bellcrank). The phenolic material and bronze bushings are provided in the hardware kit supplied by Wicks Aircraft Supply.
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April 9-10, 2007 ...  I spent the last couple days finishing some parts that were sitting half finished on my bench. I completed the left aileron bellcrank pivot bracket, and spacers that the wing mount blocks set against, and I did some more deburring and clean-up work on the spar caps. I also match drilled the root rib brackets as called for in the plans. I did that by measuring and pre-drilling the holes on one bracket. Then, I clamped on the second bracket and carefully lined everything up. I held the whole assembly squarely to a block on my drill press table and used the pre-drilled holes as a guide on the first bracket to drill the holes on the second bracket.
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Paint Ideas, Page 1
Paint Ideas, Page 2
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"Why Build?"
"Why a Sonex?"
"Experimental" Aircraft?
Helpful Links
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VS Airframe & Rudder
Rudder & VS Skin
VS Fiberglass Tips
VS Final Assembly
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Drawings & Shop Set-up (1)
More Shop Set-up (2)
Wing Hoist
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Horiz. Stabilizer, Airframe
Elevator Control Horn
Elevator Assembly
Horizontal Stabilizer, Skin
HS Hinge & Tips (1)
Horiz. Stabilizer, Tips
HS Final Assembly
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