Dave's Sonex Builders Log

Today I started on the wing rib installation. I began by finding all of the ribs for the right hand wing. I then put the spar on top of two 2x4s that I had screwed to the bench with the forward side up. One by one, I located the ribs and then drilled the pilot holes top and bottom. Next, I marked the centerline on each of the .032 spacers and then drilled the pilot holes in them. Following the .032 spacers were .125 spacers. After drilling all of the pilot holes I turned the spar over and marked the center line for the rivets on the end of each rib. Then I pilot drilled the ribs using the rear spar.

Today I worked on the spars again. I was cleaning up the minor scratches from assembly, torquing all of the fasteners, and generally getting things ready for the assembly of the wings. I completed all of the last riveting and assembly. The only thing left is the final up drilling to 1/4 inch which I need to do when the weather will allow me to extend the spars outside the garage again.

I completed drilling the 3/16 inch hole through each of the wing attach points using the 3/16 hole in the attach blocks as adrill bushing. I had not up drilled the spar web earlier. After up drilling the attach points I married the spars for the first time. All of the holes lined up very well. I up drilled the three remaining holes to #30 then to #21. Finally I up drilled the center hole to 3/16 of an inch. I decide to take things apart at this point to check things out. All looked good so I decided to up drill the remaining two holes to 3/16.

I finished all of the rivets except for the tip web assembly.

I completed all of the rivets in the inboard end web doublers. I finished about half of the remaining rivets today.

I finished all of the solid rivets in the W10-05 web doubler.

I finished all of the flush rivets in the right main spar.

Continued installing flush rivets.