Build Log for Sonex 0849B
Decided to solve oil cooler clearance issue by moving oil cooler up by about 5/8″. Removed oil cooler bracket from bottom of engine and remade bracket from 1.5″ x 1.5″ aluminum angle stock with shorter leg. Installed new bracket on…
Began fitment of lower cowl by marking out locations for gear legs and fuel drain. Slid lower cowl into place and measured front face of cowl offset by approximately 1″. Trimmed back edges of cowl 1/2″ at a time while…
Clecoed forward fuselage floor back onto fuselage to start under seat component layout. Made riser mounts for ADSB, transponder, and com boxes so that nutplates could be used out of scrap aluminum. Riveted mounts to fuselage floor behind seat pan…
Began rigging flaps for final installation by trimming flap pushrod length from 3″ to 2″ to allow more adjustment of rod ends. Removed flap motor from drive tube for easier access and started by testing position of LH flap. Adjusted…
With help, mounted left and right wing assemblies onto fuselage. Attempted to add weatherstripping on inside edges of wings but there wasn’t enough clearance; will likely seal gaps with tape later on. Before sliding wings fully together, connected wing root…
Removed wings from wing stand and set onto saw horses. Assembled aileron push rods and filed thrust bearings down for 0.01″ clearance between bushing and bell crank plate and installed assembly onto LH aileron. Slightly enlarged counterweight opening in rear…
Partially wired flap switch on bench and added extra leads to make installation into panel easier. Installed flap switch into panel and connected ground and power wires. Decided to share ground with alternator reset switch so ran additional wire to…
Crimped new 4 gauge starter cable onto cut portion with heat sink. Installed starter motor onto engine and ran cable down the oil breather line to starter solenoid. Briefly checked starter function. Created 4 intercylinder baffle plates based on forum…
Assembled paint fixture to hang ailerons from. Suspended RH aileron from fixture and bolted lead counterweight onto bracket. Checked levelness per plans and did not need to remove any material. Repeated process for LH aileron and drilled one 3/16″ hole…
Terminated amp shunt wires and tachometer lead by installing inline fuse holders with 1 amp fuses. Ran voltage regulator reset line from panel to voltage regulator. Hours Worked: 0.89
Mounted oil cooler bracket onto bottom side of intake and secured bolts with Loctite 242. Temporarily mounted oil cooler to engine then marked areas of baffling to remove for block heater and oil drain. Installed AN fittings into top of…
Drilled mounting holes for both GPS units on top of turtle deck and installed antennas using MS24693 screws. Applied clear silicone sealant around edges of GA 35 antenna to prevent water intrusion into baggage compartment; did not use sealant under…