Today I purchased a couple of lengths of 3/8" x 2-1/2" cold finished flat bar from the Metal Supermarket. I had one piece cut to 15" long and I had one piece 30" long. From the 30" long piece I cut a 2-1/2" long piece. Next I ground a 10 degree angle along one edge. I finished the edge with a file and then put a 1/8" radius on the edge. The 3/8" clamp bar replaces the 1/2" that came with the brake. This allows me to form tighter bends when they are in the same direction as required for the elevator ribs. I also made sure that I radius the top edge so that it would not dig into the first flange when forming two tight 90 degree flanges.
Cut Out More Elevator Ribs
I cut out three more elevator ribs tonight.
Elevator Ribs
I cut out three elevator rib blanks today. These were the first parts I’ve cutout without templates. I just laid out the parts using the dimension on the plans. I had a problem when I formed the first one. The second bend causes the first flange to come in contact with the bending brake. It hit a sharp edge and ended up with a gouge in the aluminum. I think I’ll make this part again and see If I can get a short piece of 3/8" x 2" or 3" cold finished flat bar to make a new slimmer clamping bar for the brake.
More Tail Ribs
I formed up some more tail ribs today. I discovered that I really didn’t need the holes in the leading edge ribs but they will actually be hidden. I formed the outer ribs for both the horizontal stabilizer and the rudder. I did these with only C-clamps holding the forming blocks together. This worked well and the parts turned out great.
Started On Tail Parts
I started cutting out the blanks for the small tail leading edge ribs and forming them.
The Last Copy Of The Number 5 Former
I finally decided to add some additional flutes to the number 5 Former. I check the rivet locations and added to more recesses to my forming block. This time the former turned out great.
Another Number 5 Former
I’m still not happy with the way the #5 former is turning out. I cant seem to get the center portion that is the highest point when installed to turn out right. It seems like it needs another flute or two. I tried again tonight with deeper flutes but it still didn’t turn out.
Cut Out Some More Turtle Deck Formers To Fix A Couple Of Mistakes
I cut out a couple of additional parts today to replace two formers that I was not happy with. The number five former has not turned out well and I don’t like the location of the straight bend in the one of the number 4 formers.
Cut Out The Last Of The Turtle Deck Formers
I cut out the last two turtle deck formers today. These were the ones that go immediately behind the cockpit.
Forming Flange on Turtle Deck Formers
Today I started forming the flanges on the turtle deck formers using my forming blocks.
Dave's Sonex Builders Log 
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