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Builder Log for ...
Sonex 963
Building a Dream!
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Page 27
Photo Courtesy of Sonex Aircraft, LLC
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July 21, 2008 ...  When I was drilling the forward holes on the upper and lower wing skins, I found that two of the holes on the top, and one hole on the bottom, landed directly over the forward root rib bracket. 
I was concerned that the shop end of the rivet would not have enough room to expand outward when the mandrel was pulled.
 
So with great effort I removed the forward root rib. Then I took my pneumatic grinder and carefully cut away the interference points on the root rib brackets The photos show the finished product. I cleaned up the edges with some sandpaper and a Scotchbrite pad.  This modification should not effect the strength of the bracket and gives me a great measure of "peace of mind."
 
After making the modifications to the Root Rib bracket, I re-assembled the Root Rib and torqued the bolts.
with the remaining time in my shop today, I worked on the right aileron; locating the rivet holes and making the cutouts for the aileron control bracket and the counterweight assembly.
 
 
 
 
 
 
 
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This photo shows the forward Root Rib installed with the cutout clearing the Cleco.
July 27, 2008 ...  With a couple hours of "wing time" today, I  was able to make a little more progress on the right aileron. The cutout for the aileron counter-balance is complete, and the aileron is completely pre-drilled and debvurred.
July 29, 2008 ...  With only a couple more hours in the shop today, I positioned the right aileron ribs and counter-balance, pre-drilled and deburred the ribs, and dimpled the aileron skin.
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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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