Build Log for Sonex 0849B
Laid out side aft side panels on top of junk F22-01 bottom aft fuselage skin to establish alignment. Set rear aft skin gap of 2.5 inches with clamped-together metal angles and set forward aft skin gap of 40 inches using…
Creation of -08 rudder stops from 1 x 0.125 bar stock. Located rudder stop on outside of aft fuselage skins and pilot drilled into place. Hours Worked: 1.12
Creation of miscellaneous aft fuselage parts per legacy plans by cutting angle stock, drilling pilot holes, and riveting -02 aft shear web assembly. -07 spacers relocated from Box 1 to WB-3L. Hours Worked: 2.48
Creation of -09 and -11 assemblies from channel stock. Since assemblies were simple, skipped documenting intermediate step of creating F23-10 and F23-13 support channels in build log. Following B model plans, took -01 tail wheel mount and drilled 3/16″ hole…
Creation of F23 miscellaneous parts per legacy plans. Made -02 bulkhead from .032 sheet rather than blank due to not knowing it was available until it was too late. Channel cut with hole cutter. -03 and -04 angles cut on…
Cut Z04-02 cross tie stock to create upper and lower cross ties. Radius’ in lower cross ties made with 1/4″ drill bit. Used legacy plans to create cross ties; no pilot holes drilled. Cut Z04-03 for lower Cross Tie #1…
Drilled and clecoed F27-09 fairlead mount blocks to #5 vertical channels. Rivets and fairleads not yet installed Hours Worked: 0.37
Attached lower and upper longerons to RH aft side skin and pilot drilled all holes. Aligned and pilot drilled vertical channels #2 – #5 on both LH and RH aft side panels. Waiting on parts to pilot drill #1 vertical…
Aligned upper longeron to LH aft side skin per plans and pilot drilled. Longeron set back 1/32″ from forward skin bend line and flush with top of skin. Lower longeron aligned along bottom edge of LH aft side skin using…
Creation of -03R lower longeron from 1x1x0.125 (120) angle stock Hours Worked: 0.84
Cut -09 fairlead mount blocks from 6″ x 12″ phenolic sheet with band saw. Drilled holes in mount blocks, counterbored rivet holes, and up drilled center hole for cable fairleads. Test fit fairleads. Will hold off on installing fairleads until…
Creation of -02L/R and -03L Longerons. Cut stock with band saw and notched forward ends with rotary tool Hours Worked: 1.03