Build Log for Sonex 0849B
Continued to work on tail fairing panels by annealing panels via sharpie method; scribbled sharpie on the panels then heated them via torch until sharpie marks began to disappear. After annealing, worked panels over a couple scrap pieces of pipe…
Began final canopy installation by drilling the rest of the hinge rivet holes in the upper longeron and installing rivets. Quick painted the rivets by hand with a brush along with other minor touchups of black paint. Updrilled canopy hinge…
Began prepping fiberglass tail fairings for final fit by marking front overhang on each fairing to note how much filler will be needed to recontour the leading edge. Removed fairings from the tail and used SuperFil to build up inside…
Began working on the tail fairing panels by cutting out template from plans on poster paper and mocking it up on the fuselage. Because the tail skin was installed upside down and needed extra trimming, will need to modify plans…
Spent most of the time getting the broken off tap out of the canopy frame. Tried to remove it with cutting fluid, heat, and punches but would not budge. Ended up purchasing two solid carbide drill bits and slowly drilling…
Updrilled canopy alignment holes in upper longeron with #F drill bit. Continued to trim, sand, and deburr canopy to achieve 1/16″ gap all around; finally achieved. Worked on latch mechanism by removing lower nylon washers to lower latch assembly slightly.…
Continued to trim and fit canopy. Matched drilled final holes in LH side of forward and aft canopy bows and realized that canopy was pulling up the frame in the front by about 1/4″. Unbolted front left corner of canopy…
Continued to trim canopy by taking small bites with 80 grit sandpaper and scotchbrite die grinder. Cleaned edges with deburring tool after each cut. Trimmed canopy so that majority of it would fit in between windshield and turtle deck. Once…
Started the tedious process of fitting and trimming the canopy. Started by marking the center of the front and rear edges of the canopy and aligning them with the fuselage center line. Scooted canopy up to the front and marked…
Began assembling canopy frame to fuselage by locating canopy frame hinge on RH longeron. Since clecoes would impede placing the canopy frame on the hinge, installed three rivets in the canopy frame hinge to make it easier to remove (if…
Rather than installing round vents in the windshield as is shown in the plans, decided to use the Vans vent sidewall kit. Worked on fresh air vents by cutting apart components from Vans vent kit and cleaning edges of parts.…
Finished installing windshield onto fuselage by installing screws from front to back, skipping last bottom screw on each side. Aligned windshield bow with top center screw and installed sandwiching strap in between. Needed to run tap through each screw hole…