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For Build updates, type "Build Update" into the blog search bar.
Build updates are posted every Thursday and cover what I did on my kit that week.

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Flying stories are irregularly posted. They are all about flying.

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Popular posts from this blog

Build Update: The Turtledeck November 2017

First off, what is a turtledeck? The answer is obvious at first, it is a wood platform on the back of the house, with a bunch of turtles sitting on it, right?

Or maybe it is what you call the deck of a cruise ship that is for turtle pleasure?

Well actually it is the round part of the plane behind the cockpit, that leads into the tail, as seen in this beautiful Sonex.

So, now that we know what a turtledeck is, I can get into how I built one!. Like everything, It started with a plans review. The turtledeck skin was made of 2 smaller skins (a left and right) and a central spine of a stiffening C-Channel. The skin then is curved to make it rounded, pretty, and aerodynamic.

I then prepared all the parts. The turtledeck formers were up to the plate first, they look like this:

I made sure that they had no stress rising scratches. (rule of thumb is that if you can catch a fingernail in the scratch, then it is too deep and must be buffed out.) Aside from that I checked them against the plans …

Build Update: Joining the Fuselage October 2017

Riveting the Fuselage side panels was extremely satisfying! After a few day's hard work, I had built up these huge 10' long metal structures! 

 I used cross ties that were akin to the vertical stiffeners. They were a C-shaped channel piece, with a prepilot drilled hole pattern that perfectly matched the spot they went. I clecoed them in place wit ha small cleco, and moved on to the next step.

And of course, once you accomplish something in your kit, don't forget to celebrate!

Build Update: Aft Fusalage October 2017

When I laid the fuselage plans out on my bedroom floor, I started at the minor details and flipped trough to full assembly. Although the plans specify how to fabricate every part you need, My project came with most of the small parts produced at the Sonex factory. In earlier kits you were given raw materials and used the plans to make each part. While the majority of my parts have been produced, I still need to check them against the plan to make sure they are built perfectly.

Starting at the back of the plans I came across the first task of the fuselage, Fabricating the rudder cable fairlead blocks. I gathered my materials, Phenolic (a composite material), drill and drillbits, and as always the pans. I laid out the dimensions for 4 blacks on the oversized piece of phenolic, I was careful to account for the thickness of the bandsaw. With the blocks cut to shape ,all the remained was to drill the 4 corner holes, and the large center hole. The blocks were set aside for later.

The next a…