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Builder Log for ...
Sonex 963
Building a Dream!
Page 12
Photo Courtesy of Sonex Aircraft, LLC
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.
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.