Dave's Sonex Builders Log

Today I continued to clean, prep, alodine and paint the components for the left main spar. I finished painting all of the small parts and got the larger web doublers alodined. Next will be the spar caps and the main spar web. I need a warm day that I can work on these outside.

I completed all of the up drilling today. Next I will take the spar apart and start the cleanup with scotch brite.

I finished up drilling the in board end of the left main spar. This is the portion with all of the web doublers. The next step will be to remove all of the doublers and then to up drill the remainder of the spar.

I completed all of the up drilling to #30 at the root end of the spar. Now I can take it apart and complete all of the rivet countersinks. I completed the counter sinking of all of the rivet holes and then proceeded to start up drilling to #21.

Today I started by cleaning up the last few angles for the right spar, then I swap the two spars on the bench so that I can start up drilling the left spar. I setup the drill press with a new #30 drill bit and proceeded to open up all of the holes at the root end of the spar. I completed about 1/2 of the holes at the root end where the various web doublers are located.

After deburring the main spar web I proceeded with the dimpling. I used my new squeezer for most of the dimples and then used a rivet, bolt and hammer to complete the last few. Next I continued the cleanup of the other web sections and then moved on to the spar caps.

I started with a bit of cleanup today and then I moved on to completing the countersinking for the counter sunk screws. After setting up my microstop I completed the countersinking of the 1/8 inch center web and the single hole in the top spar cap. With all of the drilling and countersinking complete I moved on to deburring.

Tonight I completed the up drilling on the right wing spar. Now I need to debur, dimple, alodine and rivet.

I looks like one more night and I should have all of the drilling of the spar finished.