Dave's Sonex Builders Log

I finished drilling all of the holes in the left hand leading edge wing skin. Next I started the layout on the right skin. After getting the layout completed I cut out the skin to size.

I completed laying out the outline of the skin then I cut it out. Next I worked on laying out all of the holes. With the holes all laid out I need to take a break and then come back and check some of the dimensions before drilling. After checking the holes I started the drilling completing all of the holes except for at each end.

After cleaning up and rolling and putting away the previous skin I started on the left forward wing skin. The plans indicate that the right skin is shown from the outside which means that the left is shown from the inside if I use the same layout. I completed the rough layout on one sheet and made my rough cuts using my air sheers. Next, I started to layout the cut ends using the tables provided.

Today I drilled all of the pilot holes in the skin.

Today I completed the layout of the holes in the upper left wing skin. I also trimmed the skin to size. Next time I’ll drill all of the pilot holes.

After drilling all of the pilot holes in the lower left skin I started on the upper left skin. First I identified that the plans show the inside view of the left skin. I unrolled 3 sheets and then rolled two back up. Next I determined which would be the inside. I was fortunate that the side that had some small scratches was also the side with the labeling so it was easy to decide to use this as the inside. Next I did my rough layout so that I could cut out the smaller sheet to work with. After trimming the sheet I started to layout the finished dimensions by first drawing the leading edge and the working on the outboard edge.

I picked up some more aluminum sheet yesterday. Today I am double checking all of my dimensions on the first sheet before I start drilling pilot holes. After I checked and adjusted the layout I started to drill pilot holes.

Today I continued to work on laying out all of the holes in the lower aft skin for the left wing.

I picked up the first of 6 sheets of 0.025 aluminum sheet from aircraft spruce yesterday. I’ve been waiting for it to come in so I could start on the wing skins. Today I’m going to layout one of the skins.