I cut out the first longeron doubler and sanded it.
Trim Lever
I cut, filled, sanded and drilled the trim lever. I still haven’t sorted out the exact drill sizes for AN3 and AN4 hardware yet so I stuck with pilot holes for the time being. I also put the first two bends into the lever. These are the ones that look like a joggle at the bottom where the cable attaches.
Fitting
I worked some more on the fittings today. Again working from a rough cut part to a near finished part.
Cutting 1/8 Inch Aluminum Sheet
I started today by cutting strips from the 1/8" aluminum sheet to be used for fittings.
Fitting
I made a template and rough cut one fitting on the band saw.
Brake Handle
I followed the same process as for the flap handle and this part comleted fairly quickly.
Travel Stop Plate
I made the travel stop plate. This was the last part from the 3/16" aluminum sheet.
Flap Handle
I made the flap handle today. Using one of the previously cut strips, I cleaned up the edge using the vixen file. I then cut the strip to length and added the radii at the ends using the bench sander. A little sanding, bend and scotch brite and the handle was complete.
Drive Horn
I finished bending the drive horn. I find it difficult to estimate the amount of overbend required. In this case I went a little beyond and had to hammer the bend back a bit.<br /><br /> With the bend complete I used scotch brite again to clean up the orange peel like marks in the area of the ben.
More Work on the Drive Horn
I continued working on the drive horn today. I center punched and drilled all of the pilot holes, completed the sanding and used scotch brite to clean up the part. I filed the bevel on the one edge as indicated. This appears to provide some relief when the horn is riveted to one of the ribs for the rudder.<br /><br /> With all of this work completed I started to setup for bending the drive horn.
Dave's Sonex Builders Log 
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