Build Log for Sonex 0849B
Creation of -01L/R aft fuselage skins from F26-01 skin stock. Cuts followed SXB plans to account for flap drive holes. Simple hole cut in -01L and larger hole cut in -01R for flap drive tube. Rear access holes and rudder…
Creation of vertical channels (other than -01L/R per conversion plans). Created templates for Detail A and B from .022 scrap stock to speed up process. Drilled 3/4″ hole in -02R vertical channel in the wrong location and will order replacement…
After completion of the drive rib assemblies, reclecoed assemblies together and completed final riveting. Flaps installed onto wings and appear to fit well. Hours Worked: 1.87
Up drilled drive plate attach holes to 1/4″ for AN4 hardware and clecoed AN366F-428A nutplates into place. Disassembled both drive plate ribs, deburred, and riveted assemblies together Hours Worked: 0.92
Disassembled both LH and RH flap assemblies and deburred all parts. Cut out holes in -01L/R flap skin for flap tie rod clearance and reassembled flap assemblies with clecoes. Scotchbrited and acetoned all parts. Both assemblies ready for final riveting…
Laid out flap rib holes on RH flap skin, center punched, and drilled. Bottom side skin cutout for flap pushrod marked. Lined up ribs under flap skin and began pilot drilling ribs starting with top side, upper hole on forward…
Pilot drilled and up drilled -04 flap drive plates to -02 and -03 flap ribs. Countersunk flap drive plates for CCC-44 rivets. Deburred assemblies and clecoed together pending receipt of nut plates. Cut -06L/R hinge halves from -P3 piano hinge…
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…