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Panel Redesign – Part 5
Exported panel files in Solid Works to DXF format to upload into Front Panel Designer. Imported files and began placing text on panels. Used Futura font and 10pt size in most places. Printed out front panel designs full scale and…
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Control Pushrod Assemblies
Cut aileron tube stock to size per plans for dual-stick configuration. Marked and drilled holes for pushrod end fittings, then deburred and riveted -01 main aileron pushrod assemblies. Pressed spoiler bearings into rod end bearings using vice then installed onto…
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Rear Spar Carry Through Assembly
Created F03-02, F03-05L/R, F03-08 and -04/-07 spacers from legacy plans using angle and channel stock on hand. Clecoed together -01 rear spar carry through assembly together then updrilled all holes. Disassembled part and prepped parts for final assembly. Assembled all…
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Fuel System Plumbing – Part 3
Installed 45 degree and AN fitting after fuel cube using Teflon paste. Cut a piece of solid aluminum fuel line to length and used tubing bender to bend into shape. Installed tube nut hardware on hardline and used flaring tool…
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New Workbench and Shelf
Built a rolling shelving unit and new mobile workbench for the hangar in preparation of moving the fuselage to the hangar. Hours Worked: 5.15
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Fuel System Plumbing – Part 2
Located new bulkhead hole one inch above plans measurement to ensure continuous fuel flow. Updrilled bulkhead hole to 9/16″. Created spacer from 1/8″ aluminum scrap to go between bulkhead tee fitting and nut to keep assembly from rotating. Tried to…
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Panel Redesign – Part 4
Finished designing instrument panel assembly and creating drawings to print mockups prior to manufacturing Hours Worked: 1.86
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Fuel System Plumbing – Part 1
Began plumbing the fuel system starting at the fuel tank. Used liquid teflon on all NPT threads. Made short run of fuel hose to go to bulkhead fitting. Had success creating fuel line by cutting line with cable snips and…
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Panel Redesign – Part 3
Designed cutouts in stock panel blank to make panel cover removal easier. Began recreating assembly drawing with updated panel covers. Still need to model throttle and mixture controls along with circuit breakers Hours Worked: 2.89
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Panel Redesign – Part 2
Started to redesign panel layout. Used most of old drawing but transferred and confirmed dimensions into new files. Split panel into three separate files to make import into Front Panel Designer easier. Opted to remove bottom features due to clearance…
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Fuel Tank Installation
Rinsed tank out with water to clear out debris from inside. Re-fit tank to fuselage and trimmed fuel bay area slightly more to accommodate vent fitting. Clecoed tank stop into place and confirmed tank was sitting full forward. Installed fuel…
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Panel Redesign – Part 1
After discovering issues with the panel cover, reached out to Sonex tech support and obtained original STL file. Printed out layout and compared to existing panel blank; much better fit. Converted STL into Solidworks file for panel redesign. Hours Worked:…