Dave's Sonex Builders Log

I fit all of the formers and drilled the#40 pilot holes. I now have what everyone calls the porcupine.

I pilot drilled the right hand #1 former today and started on the left hand #1 former.

Today I started by reassembling the Aft Fuselage. After it was assembled I checked and then up drilled to 3/16 the 4 holes in the tail wheel mount and the forward lower mount angle. Next I proceeded to start up drilling to #30. Later I fit the turtle deck to the aft fuselage.

I finished drilling the turtle deck and splice channel and then temporarily clecoed the assembly together. Next I dismantled the assembly so that I could go back and re-assemble the aft fuselage in preparation for up drilling.

I drilled all of the holes to connect the two turtle deck skins. Next, I worked on the slice assembly and drilled all of the holes for the brackets. Once this was complete I started to work on drilling all of the connecting holes through the top of the splice channel.

I am continuing to layout all of the holes on the first turtle deck piece. Hopefully, I can then use this as a template for the second one. After each row of holes I double checked the dimensions. I used the metric measurements as a double check for most of the dimensions except for the larger horizontal dimensions for holes 24 to 29. For these holes I measured in metric as it was easier than using imperial dimensions due to my limited measuring tools.

After dismantling the aft fuselage I cleaned up the bench and prepared to start laying out the Turtle Deck Skin.

This morning I finished all of the initial assembly of the aft fuselage as shown on sheet F21. I have the #40 pilot holes drilled and have up drilled all of the bolt holes for the AN hardware. Next, I need to tear this down, debur and then reassemble in preparation for final drilling and riveting to #30. I plan to save the riveting until I have fit the turtle deck.