Build Log for Sonex 0849B
Began final installing fuselage floors by installing AN525 hardware in the forward lower engine mounts, the aft splice plates, and the tailwheel mount bulkhead. Final installed antennas, autopilot servos, seat pans, fuselage side panels, and seats. Began riveting aft fuselage.…
Remade lower cowl hinge pin from piano hinge pin stock. Drilled mounting holes and installed Camlock receptacle in upper cowl. Installed Camlock stud into oil door and tested oil door latching; ops check good. Hours Worked: 0.67
Reassembled AeroInjector with new throttle cable and 2.5 needle. Reinstalled AeroInjector onto engine and attached controls. Reinstalled safety wire and attached new air filter element. Used safety wire to temporarily hold up oil cooler baffle for engine runs. Final installed…
Cut 0.025″ aluminum sheet and extra SNX-Z03-02 stock to create elevator pushrod cover in baggage compartment. Riveted pieces together then installed Velcro strips on baggage compartment floor and cover. Installed pushrod tunnel and verified no interference with flight controls. Cut…
Aligned aft fuselage floor and clecoed to fuselage. Riveted forward floor stiffener and gussets to firewall and forward spar tunnel zee. Clecoed forward fuselage floor onto fuselage ensuring gussets and spacers stayed aligned properly. Floor now ready to rivet. Hours…
Completed Sonex service bulletin SNX-SB-015 by replacing AN hardware in both gear legs with NAS hardware specified in service bulleting. Snugged all bolts then backed off nuts 1/4 turn before applying torque seal. Hours Worked: 0.80
Finished color sanding and polishing process with left and right side of fuselage. Used same process as previously described. Opted to not color sand blue paint on fuselage sides. Polishing complete! Hours Worked: 1.85
Setup paint booth and sprayed cowls, flap fairings, trim tab, spinner, oil door, gear leg fairings, and fuselage floors. Used previous gun settings with success and applied 2 primer coats, 3 white coats, and 4 blue coats to parts. Painting…
Wet sanded and polished LH wing, aileron, and flaps using method previously described. Spent more time on blue paint as it shows imperfections much more than the white paint. Hours Worked: 1.59
Prepped the last of the unpainted parts for paint. Sprayed upper and lower cowls with high-build primer then worked on sanding small imperfections and pin holes with 600 grit sandpaper. Both cowls got three coats of primer. Scotchbrited and cleaned…
Began the process of color sanding and buffing painted surfaces. Starting with the tail, wet sanded each surface with 1000 grit sanding sponges to knock down high spots and imperfections. Avoided sanding rivets and focusing on one area too long.…
Began process of tuning the AeroInjector. Immediately had issues getting engine started and struggled to keep it idling normally. The partial firing seems to indicate a too-rich condition with the #3 needle. Upon trying to adjust the needle, there were…