Build Log for Sonex 0849B
Began initial prop installation by enlarging holes in Jabiru prop bushings from 1/4″ to 3/8″ using drill press. Verified holes in prop did not need any reaming but needed to ream holes in spinner slightly to allow for smooth bolt…
Opted to modify internal wiring inside the Ray Allen G403 stick grips in order to isolate PTT ground from other function ground. Removed screws in stick grip in order to remove circuit board from plastic housing. The default wiring is…
Connected rudder cables to rudder horn per plans and installed rudder cable fairings on fuselage. Installed hardware for elevator push rod and lubricated bushing with LPS-1. Riveted SNB-F23-09 pushrod assembly to fuselage and verified freedom of movement in elevator control…
Epoxied tail spring rod into fuselage using 3M DP8407 metal epoxy to strengthen connection since rod had a little bit of play in tail spring mount bracket. Installed tail spring hardware. Upsized steering linkage rod holes in tail wheel assembly…
Installed aux power fuse block and SkyView splitter on underside of cross tie box with rivnuts. Worked on organizing and securing wiring under panel with zip ties and adhesive pads. Cut off unused EMS wires and secured into bundle in…
Began process of bleeding brakes using traditional pressure method but discovered half way through that tee fitting on cockpit floor was weeping slightly. Removed tubes from tee and installed new couplers on tube. Reattached tubes and tightened fittings by hand…
Soldered shielded wire bundles onto copilot headset and passenger jacks. Installed both jacks on copilot side panel and routed wires to main intercom harness. Pinned connects at harness side then tested copilot side audio. Realized the the SkyView audio wires…
After replacing hydraulic brake o-rings, reset axle nut torque by tightening nut until wheel did not wobble and slight resistance was felt on wheel. Marked castle nut location on axle then drilled cotter pin holes using 5/32″ drill bit, cylindrical…
Manufactured master cylinder mount components out of aluminum sheet and angle stock. Because the B-Model plans do not have provisions for a center mounted brake lever, used “sport trainer” plan set from the legacy plans for part dimensions. Also substituted…
Began plumbing brake system by drilling brake line pass throughs in firewall and installing rubber grommets. Routed left and right side brake lines from each wheel end to the tee located in on the forward fuselage floor. Secured brake lines…
Fabricated gear leg fairings by transferring plan measurements to 0.025″ aluminum sheet and cutting out fairing skins. Cut and pilot drilled hinge halves from P3 piano hinge stock. Clecoed hinges to fairing skins and bent skins into shape using conduit…
Laid out aft cockpit panels on front formers and marked hole locations. Cut out mounting and component holes in formers, deburred, and riveted plates to fuselage. Measured out length of pilot side headset harnesses and cut three-wire shielded cable to…