Silger Sonex

Build Log for Sonex 0849B

Build Log

  • 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…

  • Installed mixture cable into center panel section and routed cable through previously installed cable safe. Measured out approximate length and removed inner cable from jacket (making sure to carefully catch ball in cable mechanism). Trimmed outer jacket then upsized cable…

  • Diagnosed GPS175 screen issue by dissassembling unit and cleaning and reseating screen ribbon connectors; ops check good. Installed GPS harness onto back of tray and wired up ground and power connections. Installed unit and tested; ops check good. Fabricated antenna…

  • Created Garmin GPS 175 and Dynon SV-ARINC-429 harness by cutting wires to length and installing high density Garmin pins on one side and standard density D-sub pins on the other end. Referenced the wiring diagram and Dynon’s 3rd party connection…

  • Installed GPS 175 tray behind panel in preparation for GPS install. Connected SkyView WiFi adapter to back of display along with USB extension (which will be secured at a later time). Fabricated shelf for SV-ADAHRS-200 box from 0.032 sheet. Bent…

  • Installed throttle cable in center panel area. Located throttle and mixture cable pass-through locations on firewall and prepared holes for cable bulkheads. Installed both cable safes. Located throttle bellcrank assembly based on throttle cable pass through then transferred mounting holes…