Build Log for Sonex 0849B
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…
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…
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…
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…
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…
Inventory of RH Aileron previous work. Hours Worked: 0.73
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…
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.…
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…
Protected LH landing light lens with painter’s tape and fit into opening. Trimmed lens per instructions, cleaned up all edges with rotary tool, and installed lower retaining strip with double-sided tape and packing tape. Felt strip installed around landing light…
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
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…