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Builder Log for ...
Sonex 963
Building a Dream!
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Page 12
Photo Courtesy of Sonex Aircraft, LLC
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September 17, 2007 ...  I made fantastic progress today; more progress in one day than I have been able to make in any day for a while. I pre-drilled the rest of the holes in the left upper and lower spar caps, and pre-drilled all of the stiffener brackets, and the tiedown bracket.
September 18, 2007 ...  More great progress was made today. I deburred all of the spar webs, stiffener brackets, and wing attach brackets.
September 19, 2007 ...  I only got a couple hours of  "wing time"  today. So I deburred the pre-drilled holes on both left spar caps and layed out the position of the left root rib brackets. I find it is much easier to do that with the spar webs dis-assembled, so the Clecos and spar caps don't interfere when I am trying to measure. On the left spar, the root rib bracket overlaps the hole a little bit.
September 25, 2007 ...  'Lots of progress again today. I re-assembled the spar webs with Clecos, clamped the root rib brackets into place, and pre-drilled, then updrilled (with a #12 bit) through the spar webs and brackets, four center.holes. I updrilled the end holes on the root rib brackets with a #21 bit, and will complete the updriliing of those holes on final assembly of the ribs.
I spent the rest of my shop time updrilling all of the spar web parts with a #30 bit, and deburring. I then dimpled the SNX W08-02 web.
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September 9 & 10, 2007 ...  I am finally moving on to the left wing main spar!
I spent considerable time studying the drawings, then stacked the left spar webs accordingly and secured with Clecos. I pressed the upper and lower spar caps into place, using the factory provided spar cap spacers, and the spar web doubler plate to set the width. After clamping everything up, I used my handy tri-square gauge at various points to assure the spar caps were set at a uniform width. 'One quick check  to  make sure that the upper spar cap is flush on the inboard end. Everything looked great, so I started pre-drilling the spar caps with a #40 bit.
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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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