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Sonex #1284 |
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Being built by Mike Kelley—Lake Oswego, OR |
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Project Log 2010 |
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My builder log was getting too long for 1 page, so I’m going to try splitting it up by the year. Just a couple of notes. I totaled about 251 building hours in 2009 over 63 days, or roughly 4 hours per day. This was OK, but I was really low on the number of days I actually was able to work on the plane. I had the kit 9 months, so I averaged only 7 days a month! Way too low. On the bright side, I think that I’m making good progress in the time I’m spending. In the meantime, I’m also trying to fly at least once a month to keep my currency.
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Date |
Hobbs |
Elapsed |
Comments |
SNX-Drawing |
Photo Log |
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Time |
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1/1/2010 |
253.57 |
2.8 |
Happy New Year! Dimpled the turtle deck skin, riveted to the brace and slid into the rear fuselage box. Drilled and cleco'd to hold in place. Enough for New Year's Day |
F19 |
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1/2/2010 |
258.76 |
5.2 |
Started on the T-Deck formers. What a pain! Finished #5 and then #1. Difficult to keep a seam from showing on the skin. |
F19 |
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1/3/2010 |
264.38 |
5.6 |
Continued on formers #2, #3 and #4. Starting to run low on 3/32" clecos. Really needed to reshape #3L to make it fit . Got them all drilled and cleco'd. Will up-drill & re-cleco next. |
F19 |
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1/6/2010 |
266.64 |
2.3 |
Updrilled to #30 & 7/64. Removed all formers. |
F19 |
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1/9/2010 |
271.89 |
5.3 |
Deburred all the formers & cleaned up.Removed the T-Deck skin. Dimpled all the parts. Put skin and #5 former back in place. Cut out and dimpled a bunch of spacers. |
F19 |
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1/10/2010 |
274.36 |
2.5 |
Cleco'd and riveted in all the formers. Decided to put in 1.5" inspection holes in the lower plate of the cross-tie box for access. |
F19 |
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1/11/2010 |
275.38 |
1.0 |
Ooops...Had to drill out rivets to get access to the 4 AN5 holes on the splice plates. Inserted the bolts and nuts. Re-Riveted! Reamed & riveted #5 former. |
F19 |
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1/13/2010 |
278.15 |
2.8 |
Riveted #1 Former. Removed the red sharpie line from the skin with mineral spirits. Needed to make some thinner spacers out of .025 skin material. |
F19 |
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1/17/2010 |
283.78 |
5.6 |
Finished up the T-Deck! Flush rivets seem to cause a little dimpling. Began to start laying out the F12 side panels |
F19, F12 |
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1/23/2010 |
286.03 |
2.3 |
Finished clamping together the F12. Question about the placement of the F14-09R on skin. Sent question to Kerry and Bob Meyers. (Note - both confirmed that I'd done it correctly and that I shouldn't worry if some of the pilot holes don't line up - MK) |
F12 |
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2/6/2010 |
293.63 |
7.6 |
Finished drilling F12. Decided to buy more material and make new gussets for cosmetics only. Updrilled, disassembled & deburred |
F12 |
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2/7/2010 |
296.2 |
2.6 |
Tried out new maroon & white scotchbrite pad by removing ink print from left F12 skin. Used mainly white & mineral spirits. Did some work on rivet gun. When I put fluid in the reservoir, it spit it out all over through the vent! Started riveting, but broke away for the Superbowl. Watched the Colts lose. |
F12 |
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2/8/2010 |
297.42 |
1.2 |
Picked up the .09 material from Metal Supermarket. Made new F15-09 & F14-10 gussets. Finished reaming to #30 and riveted. |
F12 |
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2/9/2010 |
299.06 |
1.6 |
Finished riveting. Updrilled larger holes to #11 and inserted all the hardware. Done with the F12 Right panel |
F12 |
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2/12/2010 |
304.35 |
5.3 |
Started on the left panel. Clamped, pilot drilled and cleco'd F12L. Updrilled to 7/64. |
F12 |
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2/13/2010 |
311.91 |
7.6 |
Disassembled, deburred, dimpled, and re-cleco'd. Reamed up to #30. Started riveting F12L |
F12 |
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2/14/2010 |
316.03 |
4.1 |
Valentines Day! Finished riveting. Updrilled larger holes to #11 and installed the hardware. Finished with F12 L & R! |
F12 |
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2/15/2010 |
320.35 |
4.3 |
Started F16 & F17. Realized I didn't have the 3/4" sq 6061 tube. Went out to Metal Supermarkets, but they only had 6063, so I ordered the 6061. Suspect 6063 would be OK for stiffeners anyway. Created all the clips, and bent the small stainless filler box pieces. Unsure how I'm going to bend the floor pan and firewall pieces because they don't fit in my brake. Set aside for now and move on to F16. I'll ask on Sonextalk. |
F16, F17 |
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2/16/2010 |
322.26 |
1.9 |
Made up the rest of the F16 angles and clips. Still thinking about making the larger bends. |
F16 |
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2/17/2010 |
325.11 |
2.9 |
Drilled out and cleco'd the F16-03. Then cleco'd. Updrilled to 7/64 & started dimpling. |
F16 |
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2/18/2010 |
327.31 |
2.2 |
Finished dimpling and countersinking F16-03. Bent the floor panel and firewall. Tried making a simple brake, but a mallet worked out just as well. Also bent filler box sheet. |
F16, F17 |
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2/19/2010 |
328.5 |
1.2 |
Drilled out filler box. Discovered that stainless drills best with LOW RPMs unlike aluminum. I need to decide what cowling 1/4 turn fasteners to use (Southco or Skybolt). Still waiting for stiffener material. |
F17 |
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2/20/2010 |
333.58 |
5.1 |
Reformed all the fluting on the upper firewall. Stainless works easier than aluminum! Pilot drilled all the holes. Drilled a 3/16 "placeholder" for the cowling fasteners for now. Clamped, clecod, step drilled the upper firewall. Disassembles, deburred & re-clecod. Used some gasoline-proof sealant of the filler box seams. Riveted up the hole thing! Started reviewing the F11 assemble instructions, and realized I should NOT have riveted the F14-09 angle. I was really anxious about drilling out 42 rivets per panel, but by using low RPM it went real fast. Moved the whole fuselage box onto the work table so that I can easily attach the side panels, floor pan and firewall. |
F17, F12 |
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2/21/2010 |
339.94 |
6.4 |
Attached the side panels, floor pan and firewalls (upper & lower). Pilot drilled and cleco'd. Drilled hardware holes to 3/16 and cleco'd. Repositioned on the bench for better access. The garage is starting to get a little small! |
F11 |
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2/27/2010 |
347.62 |
7.7 |
Finished F17 with 3/4" square stock for stiffeners. Located, pilot drilled and cleco'd forward Z and aft tunnel web. Located pilot drilled and cleco'd all clips and gussets. Attached the forward floor stiffeners. Updrilled all the non-dimpled holed to #30 and updrilled the dimpled holes to 7/64. |
F17, F11 |
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2/28/2010 |
348.58 |
1.0 |
Took everything apart for deburring and dimpling ! |
F11 |
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3/6/2010 |
351.34 |
2.8 |
Grrr... I happen to read over SNX-C05/C06 which tells me that I shouldn't have assembled F21 the way I did. There should be a note on F21! So, I moved over the 2 vertical braces and cosmetically covered up the remaining holes. Cleaned up some of the fuel filler gasket sealant with laquer remover. Added a 2nd regulator dedicated to dimpling pressure. |
C06 |
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6/12/2010 |
352.61 |
1.3 |
Wow. Unintentionally took a 3 month hiatus due to work, Boy Scouts, family activities and flying! The workshop was a mess so I spent a couple of hours really cleaning it up. It took me a while to get re-oriented to what I had been doing. NEVER take that much time off! Updrilled and cleaned a few parts. |
F11 |
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6/13/2010 |
355.79 |
3.2 |
Deburred and dimpled the firewall. Cleaned up and dimpled the spar tunnel and clips. Sent Sonex Tech support a question on the 3 outer rivets on F16-04. |
F11 |
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7/3/2010 |
364.96 |
9.2 |
Finished deburring and countersinking wing attach angles. Riveted forward Z tunnel. Riveted FWD fuselage to rear. Moved the whole assemble onto the table. |
F11 |
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7/4/2010 |
371.89 |
6.9 |
Attached all AN hardware on forward fuselage. Riveted firewall and sealed all the rivets/gaps with silicone. Cleco'd in rear spar tunnel Z. Moved back to the other side of the garage and sat on horses. Dimpled lower forward skin. Big Day! |
F11 |
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7/5/2010 |
379.72 |
7.8 |
Made up all the F10 parts. Need to order some pan head screws and chromate for C06 dropped seat hardware. |
F10, C06 |
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7/6/2010 |
384.6 |
4.9 |
Finished lower seat channel. Formed the "Hat" on the HF brake. Ordered the hardware & paint. |
C06 |
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7/7/2010 |
388.3 |
3.7 |
Cut and prepared the seat sling for bending. I'm going to take it out and use Chapter 105's big brake. I'm a little concerned that I should use the next size up material per some other builders suggestions. Broke the bandsaw blade & replaced. |
C06 |
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7/8/2010 |
389.97 |
1.7 |
Bent the seat sling…perfect! Finished and assembled the F10 parts, F10 done! |
C06, F10 |
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7/9/2010 |
389.97 |
0.0 |
Flew to Arlington with fellow builder Jon Crew. We flew our Grumman AA1A up for a beautiful flight. Met Dave Weber, saw 2 Sonex, and looked at paint schemes. |
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7/10/2010 |
396.05 |
6.1 |
Preassembled the C07 lower cabin items on the skin. When clamping in place, I noticed that I hadn't cut off the "ears" of the F14 seat belt attach angle. I'll need to remove to fix. |
C07 |
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7/11/2010 |
407.04 |
11.0 |
Drilled out the rivets, fixed and reassembled the seat belt attach angle. Took about an hour. Finished all of C07. Mounted the nutplates on the control rod cover Hat. Step drilled, disassembled, deburred, reassembled cleco'd & riveted. All dimpled and.or coundersunk for flush rivets, Lower skin dimpled. |
F14, C07 |
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7/12/2010 |
409.05 |
2.0 |
Decided to remake the seat slink with .032 material. Picked some up at Metal Supermarket. I used a saber saw this time instead of a fly cutter. I think it went much easier. |
C06 |
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7/13/2010 |
410.87 |
1.8 |
Started on the controls. Needed longer bushings. Spent time removing powder coating and reamin Symco bushings. |
C05 |
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7/14/2010 |
411.98 |
1.1 |
Finished up C05. Drilled and mounted the various control hardware. Turned 610-6 bushings to remove flange. |
C05 |
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7/15/2010 |
413.11 |
1.1 |
Finished the flap handle. Ground off and painted the center control flap tab.Mounted with hardware. |
C04 |
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7/17/2010 |
419.2 |
6.1 |
Completed various control details. Made lots of little parts. Took some time and organized all my hardware pieces in boxes and drawers. |
C03, C02, F08 |
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7/18/2010 |
425.22 |
6.0 |
Mape the flap detent angle. Included the 20 degree station and the "nubs" to prevent slipping. Installed the trim control. Made up, attached and riveted the piano hinge to the seat sling |
F08 |
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8/29/2010 |
430.13 |
4.9 |
Cut out the glare shield. Changed design to accommodate screw-on panel. Hung the motor mount and evenly shimmed with large flat washers. Needed about 1/8" per corner (1/16" more than nominal. NOT BAD! |
F07, P22 |
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8/30/2010 |
431.65 |
1.5 |
Step drilled and countersunk motor mount. Finished P22 |
P22 |
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9/1/2010 |
433.22 |
1.6 |
Installed the rudder pedal block and pedals. Chamfered block as required to clear weld. Pretty tight fit. Might come back and open up a little. Installed flap control. Needed to file a little off of the vertical for clearance. |
C01 |
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9/5/2010 |
438.35 |
5.1 |
Removed and filed rudder pedal block. Took several iterations to get it right. Drilled clecod disassembled, deburred and riveted in the seat sling. I used .03 material for the sling rather than .025. Needed to file the "hat" fitting over the control bar for access to the piano wire. Enlarged the F07-7/11 panel supports to fit eyeball vents. Layed out all the panel braces and ties. My son and I sit in the cockpit for the first time! Picture Day! |
F06, F07, F08 |
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9/6/2010 |
445.07 |
6.7 |
Fit the glareshield. Mounted the instrument panel with clecos. BIG MISTAKE - see 9/11 |
F06 |
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9/11/2010 |
447.87 |
2.8 |
BIG MISTAKE - I had fit it everthing up while the GS was on top the longeron…not below. Then I drilled and attached the support angles. After realizing, it took some time to work the GS in the .032 space between the mount and the longeron. |
F06 |
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9/12/2010 |
449.65 |
1.8 |
Drilled and cleco'd the glarshield. Needed to remake two of the 3 attach angles that I had drilled. Because 1 row of holes was off the thickness of the longeronn (1/8"). Removed and deburred. |
F06, F07 |
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9/18/2010 |
455.51 |
5.9 |
Install nut plates in the Glareshield panel removal. Received the SteinAir eyeball vents. Expensive but look good! Redesigned the cross-tie support piece to clear the nutplates. Added a few more rivets to compensate for removing an "ear" |
F06 |
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9/19/2010 |
461.8 |
6.3 |
Finished installing the nutplates in the cross time. Mounted panel & vents. Looking Good! Positioned, cutout & files the openings for the NACA vents. I'd picked up from Van's earlier in the week. Glued with Auto Goop. Help in place with one flush rivet fore and aft. Note - On or about the 20th I realized that I had accidentally cut out the whole NACA outline...not just the front intake. Fixable, but a major cosmetic oops! |
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9/25/2010 |
465.6 |
3.8 |
Met with TC Dan Benua. Fessed up to mistake on NACA vents. Discussed potential solutuions. Worked on the battery box. Modified design to allow side exit/access. Considering "bonding the patch instead of riveting, so I tested a couple of JBWeld bonds (5 minute vs 12 hour) |
P14 |
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10/9/2010 |
470.59 |
5.0 |
Repaired the NACA vent cutouts. Used 24 hour JBWeld with roughed up surface. Assembled the front tire. 1 tube has a leak in the seam. Will order several for spares. Notice that I need E-Glass for the push rod boot. What the ???. Went out and got some glass & resin (mistake) from local Tap plastics. Layed up initial piece to cure overnight. Assembled the nose gear. Cut out the push-rod opening in the FW. |
L02 |
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10/10/2010 |
478.54 |
8.0 |
Finished boot layup. Looks good! Primed with spray paint. Fabricated and installed brake handle, although I'm seriously considering a hand-grip hydraulic caliper brake system. May offer the machine drums on the Sonex Forum. |
L02 |
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10/16/2010 |
482.19 |
3.6 |
Better understand the "Boot" now. Instructions were not clear. I know it needs to be flexible. Made up another piece using red hi-temp RTV gasket material. Sanded off the excess JBWeld from the NACA inlets, and reattached the Van's vents. Attached the battery box to the FW. |
L02 |
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10/17/2010 |
483.63 |
1.4 |
Finished the boot and riveted onto the FW. Picked up the shop. |
L02, C01 |
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10/18-10/22 |
483.63 |
0.0 |
Spent the week designing the electrical system, laying out the firewall, and ordering system components. Fun Week, but no time logged on build. |
E01 |
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10/31/2010 |
486.54 |
2.9 |
Installed the main gear mounts. Didn't use the -10 locator tool, so hoping the factory mounts are true. Will shim later if necessary! Made the skin cut-out in place with a step bit, followed by a file. Worked pretty good and didn't take long. |
L04 |
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11/6/2010 |
493.49 |
6.9 |
Received a new Mac Tools riveter from a friend for my B-Day…Score! Finished the left side skin cutout. Decided to jump to the spars for a change of pace and scenery. Worked on the spar angle details parts and nearly finished W11. Nice to be making parts again! |
L04, W11 |
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11/7/2010 |
498.61 |
5.1 |
Finished carefully drilling the wing attach blocks and installing hardware. W11 is finished. Deburred the webs and sanded off the flash. Cleaned up the spar caps and began assembling the right hand spar. Took some nerve to start drilling after checking spacing. |
W11, W10 W9, W8 |
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11/11/2010 |
501.37 |
2.8 |
Rechecked all work with spar spacers. Jon Crew lent me 3 of his, so the work went fast. Updrilled to 1/8" and cleco'd. Need to make the W20-02/03. |
W08 |
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11/12/2010 |
504.88 |
3.5 |
Made the W20-02/03. What a pain bending! Attached t6o right spar w/ 1/8" clecos. Review all before updrilling to #21 |
W08 |
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11/13/2010 |
508.97 |
4.1 |
Assembled the maingear wheels wi the new Carlyle tubes. Test assembled the Tracy O'brien hydraulic brakes. Perfect fit! Updrilled the spar #21 or 3/16. Disassembled, to clean up. Dimpled the main web and countersunk the center and spar. |
W08 |
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11/14/2010 |
513.28 |
4.3 |
Finished spar componenets clean-up. Primed spar with Zinc Chromate. Made 2 Sonex rivet tools (one with a narrow head) and began riveting the flush rivets. Working on a concrete floor seems to work the best. |
W08 |
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11/19/2010 |
519.1 |
5.8 |
Finished riveting the right spar! After close inspection, chose to replace 3 rivets due to "quality" issues. |
W08 |
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11/20/2010 |
522.61 |
3.5 |
Took some time to remove the blue tape from the rivet heads. Because the primer was pretty dinged up, I just used Scotchbrite & spirits on the tape. Reprimed the exterior of the web. Started assembling the left spar. It's going much more quickly and smoothly than the right! Pilot drilled 3/32 and clamped all the parts together. Noted that the distance of the W20 parts is different from the right wing. I'm going to go back and verity that measurement. |
W08 |
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11/21/2010 |
526.58 |
4.0 |
Went to a friend's and welded the Tracy O'Brien torque plates onto the axles. Cleaned up with a grinder and painted with epoxy appliance paint. They look nice! Step drilled the entire spar up to #21 for rivets, 3/16 for hardware, or 1/8" for flush rivets. |
W08 |
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11/22/2010 |
532.9 |
6.3 |
Disassembled, Dimpled, Countersunk. Cleaned up all the pieces and primed. Job went much faster for 2nd spar! |
W08 |
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11/24/2010 |
539.42 |
6.5 |
Reassembled, inserted the rivets and taped. Riveted the whole spar in just a couple of hours! After inspection, needed to replace 4 rivets. While drilling out, one spun and caused an oversized hole. I decided to up-drill to the next size and use a larger rivet |
W08 |
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11/25/2010 |
542.63 |
3.2 |
Thanksgiving! Cleaned up both spars. Decided to remake the W20-02/03 rib attach angles because I'd taken the measurement from the top rather than the bottom. Easy fix by just extending the bottom angle ~1/4" longer. Re-Attached all the hardware, cleaned up with a Scotch-Brite pad and touched up the prime. Attached the spars together. Perfect fit! The holes lined up just right. I dropped a #6 nail through the 3/32 hole for alignment and clamped tight before up-drilling. I went through a progression of steps up to 1/4". However, I still managed to break one of my 1/4" bits. Took the "Ceremonial" spar picture. After taking apart, I checked the ovaling. Just a little on one hole, but well within the 3/8" it will be drilled out too. Hooray! Note - in hindsight, it was a good decision to make the spars myself. The 1st took about 22 hours and the 2nd took about 20 hours for ~42 total, but that includes making the angles, rework, priming, and some putzing around with my wheels/brakes (and other). |
W08 |
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11/26/2010 |
545.89 |
3.3 |
Sorted wing parts and started on the Bellcrank details. Sort of anti-climatic after finishing the spars. |
W21 |
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11/27/2010 |
550.4 |
4.5 |
Discovered I was missing the SF1014-6 busing due to a typo on my early Wickes hardware order. Verified all the remaining bushings, bearings and grommets. Placed another Wicks order. Drilled & cleco'd the Bellcranks to the #9 ribs. |
W21 |
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11/28/2010 |
556.15 |
5.8 |
Finished cleaning & riveting the Bellcrank assemblies except for the bushings. Made up ALL the rib gussets. That was a fun little no-brainer task. Completely assembled, cleaned, riveted and finished all the 1st four forward rib modifications |
W21, W15 |
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11/29/2010 |
559.09 |
2.9 |
Modified the 1st 5 Aft ribs and attached the gussets. Cleaned up and riveted. Done with W16. My drill press began getting intermittent on starting. Traced it down to a bad motor switch. Will head to "The Shack" to get a replacement. If they don't have, I may use one of my Carling 10A toggle switches ordered for my panel. |
W16 |
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11/30/2010 |
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Spent a little un-logged time thinking of ways to rig the wings while still in my garage this winter. I'll need to get the OK from my wife first! |
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12/1/2010 |
561.81 |
2.7 |
Replaced the drill press switch with the highest amp-rated one from Radio Shack. Got a DPST and doubled up the circuit. Made up all the rear spar detail parts and cleaned. Layed out and cut to length the rear spar channel. |
W13, W12 |
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12/2/2010 |
568.35 |
6.5 |
Assembled, drilled, cleco'd cleaned & riveted. Rear spars complete! |
W12 |
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12/5/2010 |
571.95 |
3.6 |
Made up gussetts for root ribs . Per suggestion, will wait to cut off the end until I hand the ribs and get a real measurement. Finished installing the 1014 busing on the W21 bellcranks. |
W17, W21 |
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12/8/2010 |
575.75 |
3.8 |
Carefully cut out the flap forms. Finished all the flap details and began to drill & cleco the flap together. Much easier and faster than when I started on the elevators! |
W06, W05 |
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12/10/2010 |
577.87 |
2.1 |
Attached piano hinge to Right flap. Assembled and drilled Left flap. Attached hinge. |
W05 |
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12/11/2010 |
581.58 |
3.7 |
Up drilled both flaps. Cleaned, dimpled, reassembled and riveted left flap. Potential local builder stopped by for a look at the project. Short day…dinner guests tonight! |
W05 |
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12/12/2010 |
584.4 |
2.8 |
Finished up right flap. Decided to use some re-enforcing channel to correct for a couple of holes that were off rather than remake a rib that had slipped during drilling. It may have been difficult to exactly match the exiting ribs. Started layout of the W4 aileron parts |
W05, W04 |
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12/18/2010 |
589.76 |
5.4 |
Cutout and finished all the aileron details. Special care was taken cutting the forms. |
W04 |
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12/19/2010 |
594.03 |
4.3 |
Assembled the aileron counterweights. Never realized that lead was so difficult to work with. Added the cutout in the form for the counterweight. |
W04 |
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12/21/2010 |
597.88 |
3.9 |
Assembled the ailerons with clecos. Add the hinge. Disassembled and started dimpling. |
W04 |
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12/22/2010 |
602.65 |
4.8 |
Finished dimpling and riveted both ailerons. I'm holding off on the end cap until the wing is assembled and I can verify all the alignments. Same goes with the wing tip. Started laying out all the ribs and spar pieces for the right wing. Modified the spar spacer to include all the rivet holes. Was able to cleco everything together using existing 3/32 pilot holes. |
W04, W14 |
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12/24/2010 |
608.9 |
6.3 |
Vertically aligned all the rib tops and holes needed to clamp a few while updrilling to #30. Created and attached with clecos the right root rib. Removed the angle from the spar to make it easier. |
W14, W17 |
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12/28/2010 |
614.75 |
5.9 |
Rib by rib, disassembled, cleaned up, and reassembled in preparation fro riveting. Attached the clips for holding the pitot line. Deciding whether to include clips for an AOA system. Riveted everything together. Had the teenage son of a friend come over and taught him about clecos and riveting. Began assembling the left wing. |
W14 |
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12/29/2010 |
620.11 |
5.4 |
Vertically aligned all the rib tops and holes needed to clamp a few while updrilling to #30. Created and attached with clecos the left root rib. Removed the angle from the spar to make it easier. Ready the clean and rivet. |
W14, W17 |
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12/30/2010 |
625.74 |
5.6 |
Rib by rib, disassembled, cleaned up, and reassembled in preparation fro riveting. Attached the clips for holding the pitot line. Included clips for an AOA system. W14 done! Suspended Left structure from the ceiling. Assembled new saw horses and leveled right wing. Clamped on lower skin. |
W07 |
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12/31/2010 |
628.8 |
3.1 |
Drilled and cleco'd the lower skin. Continually checked level & square. Then clamped on upper skin, drilled and cleco'd. Pilot drilled all holes except main spar. Happy New Years Eve. |
W07 |
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