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Builder Log for ...
Sonex 963
Building a Dream!
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Page 28
Photo Courtesy of Sonex Aircraft, LLC
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August 2, 2008 ... I  thought that I would finish assembling the right aileron. However, while fitting the tip rib I found that it does not fit perfectly to my satisfaction. There is a 7/32 inch gap toward the top on the forward edge. I checked the tip rib against the drawings but found no discrepancies. I will probably scatch build this part.
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August 4 , 2008 ... I squeezed in a couple hours of "wing time" this afternoon. With the right aileron temporarily on hold (awaiting sheet metal on order), I decided to pull the left wing leading edge out of the box and dimple the rear edges that attach to the spar caps. I am anxious to see how that is going to fit.
... Looks really good on the top side .....
August 9 , 2008 ... I received the .025 aluminun sheet metal on Thursday, but I am still pretty anxious to finish my fit test of the leading edge, so I pressed on with that today. I followed the same technique that Jeff Shultz and other builders have used to pull the leading edge skin into place. I set a 2 X 2 x 8 FT. board along the inside of the rear spar and set another on top of the leading edge. I wrapped cargo straps around the wing (3 places) and evenly tightened the straps. The holes on the spar cap and the skin edges  lined up perfectly. Lining up the laser holes over the forward ribs (centerline) was a snap, so I went ahead and pre-drilled and clecoed the ribs .
I am so happy with the fit and finish of the wing skins. I will say  it again ... the kit is worth every dime! It really simplifies the build process.
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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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