Build Log for Sonex 0849B
Manufactured master cylinder mount components out of aluminum sheet and angle stock. Because the B-Model plans do not have provisions for a center mounted brake lever, used “sport trainer” plan set from the legacy plans for part dimensions. Also substituted…
Began plumbing brake system by drilling brake line pass throughs in firewall and installing rubber grommets. Routed left and right side brake lines from each wheel end to the tee located in on the forward fuselage floor. Secured brake lines…
Fabricated gear leg fairings by transferring plan measurements to 0.025″ aluminum sheet and cutting out fairing skins. Cut and pilot drilled hinge halves from P3 piano hinge stock. Clecoed hinges to fairing skins and bent skins into shape using conduit…
Laid out aft cockpit panels on front formers and marked hole locations. Cut out mounting and component holes in formers, deburred, and riveted plates to fuselage. Measured out length of pilot side headset harnesses and cut three-wire shielded cable to…
Removed RH side panel cover and finished wiring all circuit breakers and power feeds. Installed power outlet on RH side of panel. Left feed wires for autopilot and aux power panel for now. Installed pre-fabricated transponder and ADS-B harnesses and…
Completed wiring harness for the SV-COM-T25 starting at the com radio side. Began harnesses for SV-COM panel and the SV-INTERCOM as well. Will finish populating other harness later. Hours Worked: 2.80
Installed rubber baffle material onto oil cooler duct. Installed EGT and CHT sensors onto engine and completed FWF wiring harness routing (other than oil pan heater). Verified temp probe operation with SkyView system then secured wires and routing in engine…
Installed rubber baffle sections onto engine cylinder baffles with AAP rivets. Test fit baffles back onto engine and checked clearances. Installed spark plug wire grommets onto spark plug harnesses. Hours Worked: 2.27
Continued to trim upper cowl to reach alignment with lower cowl. Removed lower cowl to clearance prop opening a little more. Used the bandfile belt sander for the last few passes which resulted in a slightly cleaner edge on the…
Began fitting upper cowl by placing onto lower cowl and notating baffling interference. Trimmed front of baffles by about half an inch and rechecked clearances. Made the determination that tucking upper cowl under the windshield skirt will likely make removing…
Fabricated transponder and com antenna cables from parts then installed into airframe. Secured cables to rear spar carry through with adhesive pads. Hours Worked: 1.85
Aligned the cowl into its final place then pilot drilled side hinges to cowl. Initially only pilot drilled a few holes due to space constraints. Pilot drilled a few holes in the bottom cowl hinge half by using flashlight method…