Wings
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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…
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LH Aileron Inspection
Inventory of existing LH aileron assembly. As noted with RH aileron, skin trimmed slightly longer than specified in plans. Drilled out existing LH aileron tip rib and marked and trimmed LH aileron skin. Two rivets found missing from -06L hinge half and finished in place. LH aileron skin then prepped and deburred for new tip…
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Aileron Tip Ribs – Part 2
Due to geometry of SNB version of tip rib, fabricated .032″ spacer and installed in between tip rib and forward part of RH aileron skin. Up drilled RH aileron tip rib and riveted to RH aileron assembly. Used rotary tool to slightly enlarge counterweight opening in RH rear spar. Scotchbrited and acetoned RH completed RH…
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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…
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Aileron Hinge Replacement
Examined RH aileron assembly. Determined that aileron hinge half was not to plan and was improperly aligned with top edge. Drilled out hinge half and replaced with new hinge using strap duplicator to match holes. Leveled assembly on work bench and finished riveting on counterweight supports. Partially completed aileron assembled to wing and checked freedom…
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LH Wing Assembly – Part 12
Finished riveting lower side of LH wing including aft and forward skins. Installed aileron bell crank inspection cover plate using PK screws. LH wing complete! Hours Worked: 1.33
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Flap Issues
Began flap details by examining already assembled flaps. Flap drive plate needs to be replaced per wing conversion instructions. Upon removing legacy version flap drive plate, noticed holes do not line up and inboard-most rib location is different between the two sets. Will consult Sonex tech support for potential solutions. Hours Worked: 0.77
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Aileron Correction
Inspected previously assembled ailerons. Noted that the overall width of existing ailerons is larger than plans called for. Drilled out rivets in tip rib and trimmed skin to proper dimensions. Removed lead counterweights from ailerons and tested fit with wings. Noticed that aileron piano hinges are installed incorrectly and will likely need to be replaced.…
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LH Wing Assembly – Part 11
Deburred LH flap and aileron hinge halves and clecoed into place. Clecoed top of LH forward wing skin into place then flipped wing and ratcheted lower side into place. LH root doubler clecoed into place on top. Clecoed lower side into place. Re-flipped LH wing and riveted upper aft and upper half of forward wing…
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LH Wing Assembly – Part 10
Deburred and cleaned aft lower and forward wing skins along with root doubler. Tiedown hole in lower skin up drilled to 3/4″ per plans. LH forward skin dimpled. Leveled LH rib assembly on workbench and reattached alignment angle between main and rear spars. Clecoed aft lower and upper wing skins to LH rub assembly. Tiedown…
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LH Wing Rib Assembly – Part 4
Completed assembly of LH wing rib installation by prepping and riveting forward and aft ribs #6 – #12. Rear spar deburred, cleaned, and riveted to rib assembly. LH aft root rib riveted to rear spar. Hours Worked: 3.49