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Builder Log for ...
Sonex 963
Building a Dream!
Page 26
Photo Courtesy of Sonex Aircraft, LLC
June 9, 2008 ... Today I removed the bottom skin and spent most of my shop time dimpling the left wing, aft ribs. In the
process, I discovered that the rivet holes on rib #9, land almost directly over the rear aileron bellcrank stiffener bracket (yellow
arrow). I remember hearing that other builders have encountered the same situation. I drilled out the rivets
to remove the bracket and made a half-round cutout which will allow room for the dimple and "shop end" of the rivet. I then riveted
the stiffener bracket back on to the rib. This modification will not conflict in any way with the strength or function of the stiffener
bracket.
June 24, 2008 ... The pace of life has finally slowed down a bit and I was able to get a little "wing time" today, which
was spent on deburring and dimpling the lower wing skin. I also did some work on the parts for the right aileron counterweight.
June 30, 2008 ... I updrilled all of the holes on the bottom spar cap to #30, then using my trusty Microstop, I started
to bore the countersinks on the lower spar cap. The drawings don't call for these holes to be countersunk, but I am flush riveting
my Sonex.
July 1, 2008 ... The rest of the holes on the lower spar cap are now countersunk. And I did a little more work on the right
aileron counterweight assembly.
July 14, 2008 ... Today was a productive day in my shop. I drilled the bolt holes in the lead weight. and assembled
the right aileron counterweight. I finished the day with dimpling the upper skin (left wing).
July 20, 2008 ... I was able to squeeze in a couple hours of "wing time" this afternoon. So I dimpled the upper side
of all of the ribs.