sonexproject.com -  A construction log for Sonex #1005



Last update:  05/05/2008 - I've shifted gears now that I've analyzed my storage situation.  I'm going to knock out the wings before the fuselage because they'll be much easier to store while I'm working on the fuse.

Note:  this is a work in progress - please feel free to email comments, questions, corrections, etc.

About the Project

Leading edge vacuum forming video added to the builder resources page.  Be sure to check it out.

Builder Resources

The Beginning

01-22-2007 - The Kit Arrives
01-23-2007 - Unpacking and Inventory
01-24-2007 - Garage Organization
01-25-2007 - Tools & Plans Table

Tail Feathers

01-26-2007 - Rudder Drive Horn
01-27-2007 - Rudder Drive Horn - First Cleco & Rivet
01-28-2007 - Final Assembly of the Rudder Drive Horn

Horizontal Stabilizer

01-29-2007 - Tools & Brackets
01-30-2007 - Horizontal Stabilizer Bracket & Front Spar
01-31-2007 - Horizontal Stabilzer Ribs
02-01-2007 - More Stabilzer Rib Work
02-03-2007 - Bad HF Air Riveter
02-04-2007 - Horizontal Stab Ribs & Beginning Assembly
02-06-2007 - Front Spar Channel & Spar Drilling
02-07-2007 - Front Spar Cleco Assembly
02-08-2007 - Riveting the Front Spar
02-10-2007 - Rear Spar
02-11-2007 - Assembling the Frame
02-12-2007 - Initial Layout of the Skins
02-15-2007 - Riveting the H-Stab Frame & Pilot Drilling the LH Skin
02-17-2007 - Pilot Drilling the RH Skin & Riveting the Inner Ribs
02-18-2007 - Final Drilling and Riveting of the Top H-stab Skins
02-20-2007 - Drilling and Clecoing the Bottom H-Stab Skins
02-22-2007 - Skinning the H-Stab

Vertical Stabilzer

02-26-2007 - Cutting the Channels
02-27-2007 - Vertical Stab Channel and Clips
03-01-2007 - Vertical Stab Frame
03-03-2007 - Front Spar & Clips
03-07-2007 - Replacement Aileron Pushrods from Sonex
03-08-2007 - Vertical Stabilizer Rear Spar & Ribs
03-17-2007 - 4x10 Work Table

Forward Fuselage

03-18-2007 - Kit Inventory & Beginning Front Fuse Sides
03-20-2007 - Lower Motor Mounts
03-23-2007 - Lower Motor Mounts
03-28-2007 - Motor Mounts & Replacement Front Fuse Skin
04-01-2007 - Motor Mounts & Rudder Pedal Mounts
04-02-2007 - Rudder Pedal Angle & Skin Spacers
04-03-2007 - Flap Drive Mounts
04-24-2007 - Flap Drive Mounts & Beginning Aft Fuse

Aft Fuselage

04-26-2007 - Aft Fuse Vertical Channels
04-29-2007 - Aft Fuse Vertical Channels
05-01-2007 - Aft Fuse Zee Channels
05-12-2007 - Aft Fuse Zee Channels & Longerons
05-13-2007 - Aft Fuse Longerons & Splice Clips
05-22-2007 - Aft Fuse Splice Plates

Wings

04-12-2008 - Root Rib Attach Angles & New Shop Pictures
04-13-2008 - Root Rib Attach Angles
04-24-2008 - Aft Spar Root Rib Attach Angles
04-29-2008 - Aft Spar Tip Rib Attach Angles
04-30-2008 - Aft Spar Root Rib Attach Angles
05-04-2008 - Aft Spar Ends
05-05-2008 - Right Aft Spar Channel



Old Status Updates (for reference only)

01-18-2008 UPDATE - the lameness continues... We moved into the new house September 30th 2007 - and I've been painting & fixing since then.  I'm finally getting to a point where I will soon have time to work on the plane.  If I just didn't have a job to get in the way I'd have a lot more time to work on my own projects :)

09-13-2007 UPDATE - wow - last update 6-15-07... ok... I'm lame... I been cheating on my Sonex - with a HOUSE... Katie & I have gone from renters to homeowners - meaning I've spent very little time w/the Sonex.  It is very lonely in the garage.  After finishing flight training we spent most weekends (and evenings) house hunting - that took most of my Sonex time.  Finally we've found one that meets our requiremens (and our budget).  We've been lucky enough to have a month overlap between the apartment and house so I've been spending all my free time cleaning/painting/repairing.  Once we move I've promised myself I will spend at least 2 evenings a week working on the plane.  I'm going to get this project finished (eventually).  Now if I can just figure out how to move all of this mess...

06-05-2007 UPDATE - I passed my PPL checkride this afternoon!!!  It was windy and bumpy in Huntsville, AL (28009G16KT - RW36) but I sufficently pleased the DE and I now have my temp cert in hand.  Work can now resume full speed on the Sonex - expect updates soon!

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