Welcome to the build log for Sonex 0849B. This blog serves as a detailed chronicle of my exciting, and at times challenging, journey of building a Sonex experimental aircraft. Owning and building an aircraft has always been a dream of mine and I stumbled upon an opportunity in 2024 to make it a reality.
My approach to this project is somewhat unique, which I believe adds an interesting dimension to the typical homebuilt aircraft story. Rather than starting with a brand-new kit, I acquired this project as a partially completed “legacy” kit through a friend who is the president of the local EAA chapter. The kit was purchased from Sonex in 2004 by a local high school to be assembled as part of their aviation technologies course. After interest declined in the course, the partially completed kit was donated to the local EAA chapter where it sat for a few years as a chapter project that never came to be. This presented both an opportunity and a set of distinct considerations. The opportunity lay in potentially accelerating certain early stages of the build and acquiring the initial components. However, it also meant inheriting the work of previous builders (high schoolers no less), which comes with its own set of investigations and potential rework.
Driven by a desire to incorporate the latest advancements and improvements offered by the manufacturer, I made a significant decision early on: to upgrade this legacy airframe to the newer “B” model. This undertaking involves the use of official conversion kits provided by the manufacturer. These kits are designed to bring the older design up to the current standards, offering enhanced performance, updated features, and often improved buildability in certain areas. Over the years, parts of the original kit were misplaced and lost to time so at the point I was going to need to reorder components, I might as well upgrade in the process to the newer version of the Sonex.
A Word of Caution: My Path Will Not Be Your Path
It is absolutely vital for anyone following this blog to understand that my specific experience is just that – mine. The beauty, and sometimes the frustration, of experimental aircraft building lies in the fact that no two projects are exactly alike. This is especially true in my case, given that I am working with a second-hand kit and undertaking significant modifications through conversion kits.
The way these conversion kits integrate with a pre-existing legacy build can vary depending on the stage of completion of the original kit. For example, some of the parts I purchased were contained in the original “machined angle component kit” but, as I found out throughout the build, that was not complete. Additionally, you’ll notice in my build log that the original owner did not opt for the pre-assembled spars option and I needed to build them from plans. Later on in the process, you’ll see me have to manufacture legacy parts that were included in the newer b-model kits. Therefore, the steps I take, the challenges I encounter, and the solutions I implement may not be directly applicable to other similar projects. Each conversion process will have its own nuances and require independent assessment.
How to Get the Most out of my Build Log
The reason I decided to publicly publish my build log is to help other builders as they complete their own projects. Posts on the main page appear in chronological order as I progress through my own project. If you are looking for a specific keyword, feel free to use the search box on the main page to try and find what you are looking for. Each post references a specific page of the plans and are sorted on the “Tasks” page. Head there if you are looking for information on a specific task. At the end of each build log is a list of each part used. You can click on the part name to take you to every entry that involves that part.
All of the pictures on the website are uploaded in full resolution to help you spot details you might be looking for. Click on an image to have it expanded so you can take a better look.
Feel free to interact or comment on any of the posts and I will do my best to respond. Otherwise, use the “contact me” link at the top of the website to send me an email.
Important Disclaimer: Information for Reference Only
The information, technical details, photographs, personal anecdotes, and opinions shared on my build log are intended solely for informational and reference purposes. This blog is a documentation of my personal journey as an amateur aircraft builder. I am not a certified aircraft mechanic, engineer, or aviation professional. The content presented here should not be construed as expert advice, instructions, or recommendations for your own aircraft building projects.
Building and modifying aircraft is a complex and potentially dangerous undertaking that requires meticulous attention to detail, adherence to official manufacturer guidelines, and compliance with all relevant aviation regulations. Under no circumstances should you rely solely on the information provided on this blog for your own aircraft construction, maintenance, or modification endeavors. I have reached out to Sonex technical support team a number of times during this build and have had nothing but great advice in a timely manner.
Always consult the official plans provided by the aircraft manufacturer, seek guidance from qualified and experienced aviation professionals, and adhere strictly to the regulations set forth by your local aviation authorities. Your safety and the airworthiness of your aircraft are paramount.