Dave's Sonex Builders Log

I continued working on the left wing tip today. I worked the flutes a bit to improve the fit of the 45 degree flange and then transfered the pilot holes from the top skin to the flange. I plan to keep the tip skin a bit short on the top side so that the radius is visible. I think this will provide the cleanest look.

I’ve been working on my wing tips for a little while now. At first I wanted to make a one piece wing tip out of aluminum and I started this by creating a cardboard template of the wing tip opening. I decided that a one piece tip would be rather difficult and I was especially worried about forming the flanges. After looking at some other plans that I have (Zodiac XL) I decided to form the flanges as separate angles. These will have nut plates installed so they can be screwed to the wing skins and then I will rivet a single flat sheet of aluminum to the angles to form the wing tip. So far I’ve made up three of the angles and pilot drilled two of them.

I traced and cutout the wing access cover. Next I drilled the four pilot holes. I now need to mount the nut plates but first I need a band saw blade.

Today I continued on working on the rear edge of the left wing. I retrieved the flaps and proceeded to fit the hinge for the flaps. I discovered one of my hinges was too short but I had one that worked. I fit the hinge and pilot drilled to #40 then up drilled to #30. A this point I think I have the wing ready to debur and then rivet. I still need to countersink the holes for the tip ribs/skin and finish the up drilling.

I finished stripping the plastic from the bottom of the left wing then proceeded to up drill the skins. I completed most of the up drilling on the bottom side. Next, I need to get down the flap and fit the hinge in order to complete the up drilling.

I installed the hinge for the aileron and then proceeded to up drill the remaining holes in the top of the wing to #30. I flipped the wing over and started removing plastic from the bottom side.

In order to get ready for riveting I removed the plastic covering on the wing skins in the areas of the rivet lines using a soldering iron to melt the plastic sheet. With the plastic removed I proceeded to up drill the rivet holes to #30. Next, I unpacked the ailerons so that I could get the second half of the hinge that needed to be attached to the wing and started to mark it’s location.

Tonight I continued to work on the landing light. I drilled and deburred the retainer for the bottom of the lense cover.