Build Log for Sonex 0849B
Bent exhaust tunnels and outlet lips from firewall forward kit blanks. Made flange tool out of scrap phenolic. Bent tunnel sides using bending brake then bent mounting flanges using homemade flange tool. Aligned exhaust tunnels onto newly cut cowl openings…
Removed upper cowl from lower cowl again and began sanding upper cowl. Started with 60 grit and moved up to 240 grit sandpaper to better blend transition area. Finished sanding with upper cowl mocked up onto lower cowl to better…
After allowing epoxy to cure, used 60 grit sandpaper and hand sanding block to rough shape cowl curvature and knock down spatter and high spots. Tried to focus on transition areas between existing cowl and new work to make transition…
Placed 1.125″ Adel clamps around LH landing gear leg and marked approximate mounting hole position on gear leg fairing. Removed fairing and drilled mounting hole in fairing. Temporarily bolted fairing to landing gear leg to mark second mount hole location…
After leaving the fiberglass to cure for a couple days, marked rough cut line and gently pried the top cowling off of the bottom cowling without incident. Rough sanded upper cowl using 60 grit sand paper to level bottom edge…
Prepped upper cowl for fiberglass work by cleaning areas with acetone and adding more packing tape to lower cowl. Cut (3) 32″ strips of fiberglass for each side of the cowl at 1.25, 1.50, and 1.75 inches wide. Mixed small…
Did some rough trimming of the RH side fuselage side panel to verify routing path of pitot/aoa tubes. Disconnected RH rudder cable to ensure all bundles were behind it then reconnected cable to rudder pedal. Drilled 1/2″ holes through fuselage…
Leveled fuselage then temporarily installed pitot mount into RH wing to calculate spacer size needed to level pitot tube. Made 2 0.125″ spacers (0.25″ total) out of 0.125″ aluminum sheet to place under back side of pitot tube mount. Installed…
Located and drilled hole for ELT antenna on aft portion of turtle deck. Secured antenna to fuselage then routed and connected coax cable from antenna to ELT. Cut hole in RH #1 former for RCPI and drilled mounting holes. Installed…
Continued to sand lower edge of upper cowling in preparation of lengthening the lower edge using hand and orbital sander with 60 grit. Finished rough sanding with 120 grit discs; should now be ready for fiberglass work. Cleaned upper edge…
Began prepping upper cowl for fiberglass work by removing prop and spinner from engine then reinstalling lower cowl and cowl alignment spacer. Placed upper cowl into approximate position and secured to spacer. Traced 1.5″ line along upper cowl to mark…
Configuration: Cowl removed; inspection covers for all fuel pumps and valves removed. Procedures: Results: Overall fuel flow rate from 19.25 gallons to 0.00 gallons was 22.95 GPH Gallons Time (Sec) Time (Total) Rate (GPH) 19.25 0.00 0.00 0 18 126.81…