Build Log for Sonex 0849B
Setup paint booth and moved fuselage/canopy parts into spray booth. Cleaned all parts with pre paint prep and discovered that not all parts would fit at the same time. Sprayed two coats of primer on black fuselage parts and windshield…
Prepped fuselage and windshield/canopy parts for black paint. Masked off glareshield and cabin area with painters tape then taped drop cloth over tape lines. Scotchbrited miscellaneous canopy and windshield parts in preparation for paint. Hours Worked: 1.94
Tested fuselage side panels by trimming RH side panel from ABS sheet and making small adjustments to test fit. Hours Worked: 1.50
Removed GPS175 tray from panel for better access. Marked out alignment guides on glareshield for compass. Pilot drilled holes using compass as template then updrilled for #6 screws. Used nut plate drill guide to drill nutplate mounting holes. Deburred holes…
Began prepping the windshield components for paint and final assembly by updrilling and deburring the windshield skirt. Enlarged fuel door hole and installed Southco receptacle for fuel door fastener with flush rivets. Then updrilled windshield bow skirt and scotchbrited. Updrilled…
Installed rivets between panel blank and cross tie fittings. Riveted lower control angle for throttle, mixture, and trim onto lower edge of panel blank. Installed temporary #6 screws into panel blank then flush riveted panel to angles. Then riveted panel…
Removed windshield components to prep for painting and updrilling. Deburred upper firewall holes. Hours Worked: 0.52
Now that all work under the aft seat pan has been completed, clecoed aft seat pan to ribs and final riveted. Hours Worked: 1.09
Began seatbelt installation by placing AN5 bolts in center seatbelt channel with grabber extension. Wrapped chrome ends of lap belts in painters tape to prevent scratching. Followed plans and placed buckle ends of seatbelt on inside. Set approximate lap belt…
Finished trim system by installing last clamp on elevator pushrod and balance spring. Will wait to adjust until flight testing occurs. Also added torque seal to elevator push rod bolts. Hours Worked: 0.32
Began trim system installation by removing lower instrument panel and drilling holes for throttle, mixture, and trim wheel. Measured and drilled hole for trim cable sleeve below seat pan. Mocked up cable run and trimmed around 18″ from cable and…
Temporarily installed control stick assembly. Pressed SF-812-3 bushings into stick to idler bar and control frame then installed idler hardware permanently and stick hardware temporarily. Verified freedom of movement and clearances with idler bar. Pressed bushing into elevator push rod…