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Builder Log for ...
Sonex 963
Building a Dream!
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Page 17
Photo Courtesy of Sonex Aircraft, LLC
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November 24 & 26, 2007 ...  I didn't  get much "wing time" last week ('Lots of holiday "Honey do's"). So I was very happy to spend some time working in the shop today. I installed the gussets on the first three inboard rib sets on the left wing.  I was really hoping to get all of the gussets on the left wing ribs, but I didn't quite make it.                                                                                                   
November 30, 2007 ...  Bummer!  I was hanging Christmas lights on my house, when the extension ladder decided to slip out from under me. In a quarter of a second I dropped about 9 or 10 feet, and broke the fibula bone in my right leg (in 2 places) which was the beginning of a rude delay in my Sonex project. I am sure glad it wasn't a "3 point landing!"
Moral of the story:  Had I been working on my airplane, I would STILL be working on my airplane!
The cartoon graphic on this webpage is the original artwork of Jeff Bucchino, and used with his permission. To view or obtain more of his creations
click here.
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January 19, 2008 ...    Today was a great day! I am finally back on both feet again, and resumed my Sonex project. It feels great to have a pneumatic riveter back in my hand again. I finished assembling the gussets  to the left wing inboard ribs; deburred, cleaned and alodined the rest of the forward ribs.                                    
January 21, 2008 ...  'Another    productive day in  the shop!   I finished deburring and alodining the left wing rear ribs, and clecoed them to the main spar.                                    
January 22, 2008 ...Okay ... Now for the great moment of truth! I set my left wing main spar on a couple adjustable work stands (purchased at the Home Depot), and fit my rear spar to the aft ribs. I  was highly curious to see if the holes I drilled in the rear spar matched up with the factory pre-drilled holes in the aft ribs. They all lined up perfectly (except 4 that were only off by 1/64th"). The #12 rib was a disaster, however!  All 4 of those holes were off by 3/32! I am not quite sure where my mind was at when  I was drilling those holes!   Now, I will have to re-make the outboard spar extension, but this time I am going to use the pre-drilled holes in the aft rib to locate the holes in the rear spar extension.  
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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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