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Sonex #1284 |
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Being built by Mike Kelley—Lake Oswego, OR |
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Project Log 2009 |
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This is the first-time journey to fulfill a lifetime dream.
My goal is to build a Tri-Gear Sonex Sport Trainer, with dual controls and using the Jabiru 3300 120HP 6 cyl engine. |
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Date |
Hobbs Time |
Elapsed |
Comments |
SNX-Drawing |
Photo |
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Time |
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3/26/2009 |
0 |
0.0 |
Took my brand-new plans apart, folded them up, and put them in plastic envelopes. |
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3/28/2009 |
0 |
0.0 |
Workshop preparation. I built a drawing holder, and started getting my tools organized. I also built an AC Hobbs meter on a switch so that I’d properly record my time. |
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4/1/2009 |
0 |
0.0 |
Kit arrives. My sons and I unloaded, which took all of 15 minutes. The spar tube was missing and there was some damage to the sheet metal pallet. |
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4/2/2009 |
0 |
0.0 |
Spars showed up today with both end-caps off. Some spar caps were slightly dinged. Kerry said “No Worries...Scotch-Brite them out.” Started inventory & began storing kit items |
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4/4/2009 |
0 |
0.0 |
Got into the pallet and discovered that W19-01 was bent up. Got the –01 replacement on order. |
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4/6/2009 |
0 |
0.0 |
Dug a little further into the pallet and discovered that W19-02 was also slightly wrinkled. Sonex says it will straighten out OK. |
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4/9/2009 |
0 |
0.0 |
Finished inventory and put all the small parts away in see-thru plastic bins with labels. |
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4/11/2009 |
3.39 |
3.4 |
Got everything put away and started cutting angle with the chop-saw. I used a $10 laminate blade from HF which went through aluminum like butter. I sprayed just a little WB-40 for cutting lube. Blade looked like new when I was finished. |
Angle |
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4/12/2009 |
3.39 |
3.4 |
Got the shop ready to finish edges. I plan on using a flapper wheel, Scotch-Brite, bench sander and hand file. |
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4/18/2009 |
7.34 |
4.0 |
Got my first parts completed, and made my first mistake. Despite the drawings, the G01-8/9 are NOT made out of 1/8” ! |
Finished |
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4/19/2009 |
10.01 |
2.7 |
Sanded, Finished and bent most of the Tail pieces. Thick materials needed a vise and a monkey wrench! |
T4, T7, T10, T12, T13 |
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5/17/2009 |
14.81 |
4.8 |
3 week delay due to work. Got started cutting out the elevator skins and piano hinges. Made up the hole spacer from a 48” metal ruler. |
T7 |
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5/18/2009 |
19 |
4.2 |
Assembled the elevator horn, and started on the horizontal ribs |
T6, T5, T4 |
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5/19/2009 |
25.25 |
6.3 |
Finished the hor ribs, and assembled the tail rear spar |
T3 |
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5/23/2009 |
25.25 |
0.0 |
Day Off...Attended Rio Linda Fly-in! |
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5/24/2009 |
28.12 |
2.9 |
Assembled the tail forward spar |
T3 |
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5/25/2009 |
36.16 |
8.0 |
Cleco’d both elevators together. Practiced pulling flush rivets, and clamped the horizontal stab together to check measurements. |
T2 |
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5/26/2009 |
36.16 |
0.0 |
Uploaded photos & website |
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5/28/2009 |
40.22 |
4.1 |
Messed up T3-05. Put -03 too low by registering on surface. Made new T3-06. Drilled out rivets & cleaned up. Recleco'd |
T2, T3 |
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5/29/2009 |
43.68 |
3.5 |
Deburred new stabilizer. Riveted rear spar |
T2 |
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5/30/2009 |
49.28 |
5.6 |
Experimented with dimple pressures/ Dimple ~25 psi & rivet at 40 psi. Finished spars & ribs. Flush riveted elevators. |
T2 |
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5/31/2009 |
54.86 |
5.6 |
Cleco'd full horizontal stab. Elevator hinge was about 1/4" off. Decided to make. |
T2 |
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6/1/2009 |
56.13 |
1.3 |
Drilled & Cleco'd bottom side of hor stab |
T2 |
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7/4/2009 |
62.68 |
6.6 |
Dimpled hor stab |
T2 |
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7/12/2009 |
65.23 |
2.6 |
Flush riveted hor stab except hinge & tips. Countersunk hinge. Need to decide how to mount |
T2 |
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8/22/2009 |
65.23 |
0.0 |
Met with TC Dan Benua. Dan's built an RV-6A, RV-10 and is building an RV-3B. |
All |
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9/5/2009 |
72.21 |
7.0 |
Skipped working on the tips until I get Bondo. Went to Vert Stab. Immediately messed up by cutting elevator skin with wrong side up (after checking 2-3 times). Made all the ribs, assembled the horn. |
T13, T12, T11, T10, T9 |
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9/6/2009 |
77.96 |
5.8 |
Assembled the spars. First time working with AN hardware. Messed up the rear spar by cutting 1/2" too short. Remade. Will need to order material. Cleco's ribs and spar together. |
T9, T8 |
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9/7/2009 |
85.64 |
7.7 |
Deburred the spar & ribs then riveted. Dimpled the vert skin and flush riveted one side. |
T8 |
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9/10/2009 |
87.34 |
1.7 |
Dimpled other side of the vertical stabilizer. Thought a lot about how to do the tips. Made a back plate for the flush hinge rivets. |
T48, T14 |
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9/11/2009 |
88.93 |
1.6 |
Finished riveting other side of Vert Stab. Made decision to add an inverted rib as a flange for the tips. This will let me close up the stabilizers, which I did. Decided to order a bunch of additional rivets from Sonex along with rudder skin. Will also order new #41 drill bits from ACS because the ones from the Yard Store aren't cutting. |
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9/19/2009 |
96.46 |
7.5 |
Received new skin, rivets & bits. What a difference the drill bits make! Started and finished entire rudder in 1 day. |
T13, T12, T11, T10, T9 |
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9/20/2009 |
101.86 |
5.4 |
Made the rib form, and ribs for the attachment flange. Cleco'd the flange onto the top of the stab. Added a .030 spacer to get right standoff. |
T14 |
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9/26/2009 |
104.62 |
2.8 |
Cut the vertical tip. Sanded & bondo'd the vertical tip. |
T14 |
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9/28/2009 |
104.62 |
0.0 |
Received my Jabiru 3300! (See 9/26 photos) |
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10/3/2009 |
110.26 |
5.6 |
Attached the rudder to the vertical stab using the backing plate. Finished up the Hor stab. Made backing plated for flush rivets & hinges. |
T02 |
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10/11/2009 |
112.75 |
2.5 |
Fit & Cleco's the vert tail tip to the vert stab. |
T14 |
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10/18/2009 |
115.76 |
3.0 |
Made a dolly for the 3300 to be pushed around. Attached flange rib to the right side of the hor stab. Cut & fit tip. Cleco'd together. |
T14 |
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10/29/2009 |
120.94 |
5.2 |
Tested the flatness across the elevator from tip-to-tip. It was 1/4" off. Unriveted left root elevator rib from the horn. Made a rib former, and remade a new rib. Cleaned up & cleco'd. Fixed the problem! |
T06, T07 |
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10/30/2009 |
124.22 |
3.3 |
Disassembled the new rib, deburred, cleco'd & riveted. |
T06 |
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10/31/2009 |
128.07 |
3.8 |
Disassembled hor tip flanges. Cleaned up, clecod & riveted. Also fixed 2 small non-uniform bumps on leading edge rib. Drilled out rivets, created a small spacer, inserted & re-riveted. Looks better! Bondo'd & sanded the hor tips. Refitted. Found a space to hang both the hor stab/elevator & vertical stab/rudder in the workshop. |
T14 |
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11/1/2009 |
128.66 |
0.6 |
Time to move on to the fuselage & wings. Re-organized the workshop. Removed the old bench and installed a 8' x 4' from part of my kids old roadrace track platform. Found some culled wood at Home Deport for ~$1! Cleaned up everything. Finished up by cutting out some pieces for F27 01-05 |
F27 |
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11/4/2009 |
130.98 |
2.3 |
Marked up all the cut lines for the vertical channel. |
F27 |
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11/5/2009 |
135.13 |
4.2 |
Cutout & finished F27. Discovered I hadn't ordered the fairlead or snap bushings. Cut & finished the 4 phenolic pieces. |
F27 |
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11/6/2009 |
136.96 |
1.8 |
Finished & bent all the F26 parts. Really need to be careful on the mirrored parts. I'm getting very comfortable with the drawings and Sonex's conventions! |
F26 |
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11/7/2009 |
142.21 |
5.3 |
Jon Crew visited from Boring. We discussed all the aspects of building…especially avionics and panels. I cut and completed the fuselage cross ties and box. |
F24 |
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11/8/2009 |
147.94 |
5.7 |
Cut and finished all the Misc F23 parts. Took longer than I thought it would. |
F23 |
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11/9/2009 |
149.54 |
1.6 |
Started and finished all of F22. F22-05 w/ 1.5" hole was most challenging. I chose to use a bi-metal hole saw and some cutting oil. |
F22 |
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11/11/2009 |
153.09 |
3.6 |
Marked up and started making rough cuts. The mirrored parts are difficult to picture. I needed to go up to the assembly diagram (F12) to see just where the parts fit. Several parts do not have dimensions. Instructions are to model the full-size drawing. So, just copied the measurements directly onto the Right-hand part, flipped it over and marked on the Left-hand part. |
F15 |
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11/13/2009 |
160.62 |
7.5 |
Cut & finished everything but the phenolic. Drilled the -04R wrong, so I remade out of some extra angle. I've located a vendor (Metal Superstore) here in Portland, so it's no a big deal if I need to buy a few more pieces. |
F15 |
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11/14/2009 |
163.62 |
3.0 |
Cut out & finished most of the phenolic. Missing material for the F15-13, so I'll need to order. Cleaned up the entire F15 batch with a purple Scotchbright sanding wheel I discovered locally. Makes the parts looks really nice! Began laying out the raw materials for F14. Cut them to length. |
F15, F14 |
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11/15/2009 |
170.51 |
6.9 |
Worked on forward fuselage side panels. The detailed angle cuts take some time. Experimented with using an Olfa knife (box cutter) on the long channel cuts. Decided that it's much easier to rip them down with the bandsaw & then sand down to the finish line. |
F14 |
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11/21/2009 |
178.9 |
8.4 |
Made the 07 L/R, 08 L/R & 09 L/R parts. Mangled the 09 trying to open it up to 93.9 degrees using a hammer. Cut a new piece and ruined it too opening it up. Got ideas from Sonextalk. Will need to get some additional angle and a piece of pipe from Metal Supermarket. Forgot to radius a couple of F15 parts and finished them up. Replaced the bandsaw blade...wow what a difference. |
F14, F15 |
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11/23/2009 |
181.61 |
2.7 |
Using the "pipe" method, opened up the angle and then remade the F14-09 parts again. It worked great. This was the most difficult part to date. |
F14 |
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11/27/2009 |
187.15 |
5.5 |
Made the F13-06 L/R. Started the 03 L/R. My decision to use the tilt-back canopy means I will need to slot both upper longerons…not just left. Nuts…will need 2 more strike plates. |
F13 |
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11/28/2009 |
193.44 |
6.3 |
Finished all the F13 parts. Decided to substitute acrylic for the phenolic strike plates so that I can move ahead. |
F13 |
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11/29/2009 |
195.04 |
1.6 |
Finished the F20 parts. Started laying out the F25. |
F20, F25 |
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12/6/2009 |
199.77 |
4.7 |
Worked on the F25 right rear side panel. The fly-cutter from HF was not straight. Need to return or rework. Finished assembling the fairleads. Discovered that the phenolic was a little too thick for the snap ring to be fully seated. Sanded off ~1/32 and it fit fine. |
F25 |
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12/7/2009 |
202.09 |
2.3 |
Fit the splice plates onto the right side rear panel. Needed to tweak a few of the bend angles. Drilled all the pilot holes and prepared to dimple for flush rivets. Used my new #11 drill to ream the 3/16 holes. |
F25 |
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12/8/2009 |
203.85 |
1.8 |
Put the HF fly-cutter in the vise and straightened. Cut inspection side on right side. Also cut out rudder cable slot. Deburred & countersunk longerons. |
F25 |
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12/12/2009 |
211.35 |
7.5 |
Missing the CCC-46 so need to contact the factory. Dimpled all the right side skin holes. Deburred, cleco'd and riveted.Attached the Longerons. Made some nifty vertical supports from some board support stands. |
F25 |
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12/17/2009 |
213.14 |
1.8 |
Well, the factory doesn't use CCC-46. I'll recess the back and use CCC-44 to keep the flush look. Plus, the plates take hits and it'll be better if the rivets aren't sticking out. Cut out the left side inspection hole and rudder cable slots. Updrilled the left longerons and countersunk. |
F25 |
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12/18/2009 |
215.48 |
2.3 |
Re-assembled left side and riveted. Finished F25! Started clamping F21. |
F25 & F21 |
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12/21/2009 |
219.83 |
4.4 |
Squared up the rear fuselage box. Pilot drilled and cleco's lower cross ties. My son Jason helped out a little. Used the ower skin to check layout and angles.Perfect fit! Then deburred & riveted lower cross ties. Per instructions, I won't rivet lower skin until the end. Began to drill & cleco lower skin. |
F21 |
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12/22/2009 |
224.01 |
4.2 |
Finished step drilling lower skin @ 7/64". Disassembled, step drilled up to #30, and coundersunk lower longerons. Deburred and dimpled untire lower skin. Measured and clamped F23 - 9/11. |
F21 & F23 |
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12/26/2009 |
227.73 |
3.7 |
Flipped the box over and spent a lot of time getting the cross-tie box in proper position. Like a few other builders, I needed to trim off ~ 1/16" from each end at the top. I think this was because the horizontal splice-plate bend was a little too far back. After everything was lined uprilled and clecod the upper cross ties. |
F21 |
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12/27/2009 |
232.99 |
5.3 |
Began fitting and assemble of the aft shear web assembly. Reattached lower skin to keep everything true. Drilled and cleco'd the seat harness brackets. Worked a long time on the tail skid alignment. Finally took off the T12 from the vertical stab assembly and prepped it per the drawing. I recognized a small error in F23-03 and will remake the part. |
F21 |
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12/28/2009 |
235.49 |
2.5 |
Remade the F23-03. Checked the tail skid alignment one more time before I up-drilled and re-cleco'd. |
F21 |
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12/29/2009 |
240.37 |
4.9 |
Updrilled, Disassembled, deburred, & recleco'd. Also dimpled the rear skins. Touched up the pain, let dry & bolted together. |
F21 & L03 |
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12/30/2009 |
245.75 |
5.4 |
Finished updrilling, deburring and finally riveted all the cross tie members. Finished F21 - YAHOO. |
F21 |
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12/31/2009 |
250.73 |
5.0 |
New Year Eve's day! Flipped the box over removed the skin and flipped 180 to align with the drawings. Started on the turtledeck. Completed the splice assembly. Realized that I mis-cut the end angle, so remade the part. |
F19 & F20 |