emkrueger830
Fairlead Blocks
Cut -09 fairlead mount blocks from 6″ x 12″ phenolic sheet with band saw. Drilled holes in mount blocks, counterbored rivet holes, and up drilled center hole for cable fairleads. Test fit fairleads. Will hold off on installing fairleads until rudder cable installation per plan recommendation. Therefore, will not be using -10 fairlead block assembly…
Aft Fuselage Side Panel Prep – Part 3
Creation of -02L/R and -03L Longerons. Cut stock with band saw and notched forward ends with rotary tool Hours Worked: 1.03
Aft Fuselage Side Panel Prep – Part 2
Creation of -01L/R aft fuselage skins from F26-01 skin stock. Cuts followed SXB plans to account for flap drive holes. Simple hole cut in -01L and larger hole cut in -01R for flap drive tube. Rear access holes and rudder cable slots located in same position on both sets of plans. Larger holes cut with…
Aft Fuselage Side Panel Prep – Part 1
Creation of vertical channels (other than -01L/R per conversion plans). Created templates for Detail A and B from .022 scrap stock to speed up process. Drilled 3/4″ hole in -02R vertical channel in the wrong location and will order replacement from Sonex due to insufficient raw material for a spare. Cut blanks from Z03-04 and…
Flap Rebuild – Part 6
After completion of the drive rib assemblies, reclecoed assemblies together and completed final riveting. Flaps installed onto wings and appear to fit well. Hours Worked: 1.87
Flap Rebuild – Part 5
Up drilled drive plate attach holes to 1/4″ for AN4 hardware and clecoed AN366F-428A nutplates into place. Disassembled both drive plate ribs, deburred, and riveted assemblies together Hours Worked: 0.92
Flap Rebuild – Part 4
Disassembled both LH and RH flap assemblies and deburred all parts. Cut out holes in -01L/R flap skin for flap tie rod clearance and reassembled flap assemblies with clecoes. Scotchbrited and acetoned all parts. Both assemblies ready for final riveting pending completion of SNB-W06-05L/R drive plate assembly nutplate installation Hours Worked: 2.90
Flap Rebuild – Part 3
Laid out flap rib holes on RH flap skin, center punched, and drilled. Bottom side skin cutout for flap pushrod marked. Lined up ribs under flap skin and began pilot drilling ribs starting with top side, upper hole on forward side, then hinge-half strip, and finally lower side. Set 1/16″ hinge half offset by using…
Flap Rebuild – Part 2
Pilot drilled and up drilled -04 flap drive plates to -02 and -03 flap ribs. Countersunk flap drive plates for CCC-44 rivets. Deburred assemblies and clecoed together pending receipt of nut plates. Cut -06L/R hinge halves from -P3 piano hinge and pilot drilled hinge halves per plans. Although hinge halves have different part numbers, no…
Flap Rebuild – Part 1
After discussion with Sonex tech support, decided to scrap previously built flaps due to notch-out of skin on forward edge. Trimmed and deburred Z02-02 flap skin stock per plans to create -01L/R flap skins. Notches for flap pushrod yet to be cut. Mocked up -04 flap drive plates to flap ribs and pilot drilled. Discovered…
Pitot Mast Drilling
Marked mounting holes in pitot mount and tube; two per side. Drilled pilot holes with #36 drill bit. Upsized mount holes to #25 for #6 screws. Carefully tapped pitot head with 6-32 tap through mounting pads. Front left hole had screw break off inside so needed to (mostly) drill out and redrill slightly lower. Mount…
Aileron Tip Ribs – Part 1
Was able to save W04-10L tip rib from previous work and use strap duplicator to mark hole locations in new spots in aileron skin. Up drilled, deburred, and riveted LH aileron tip rib onto LH aileron assembly. Die grinded stained spots on LH aileron skin then scotchbrited and cleaned LH aileron assembly. Temporarily installed aileron…
