Dave's Sonex Builders Log

Today I completed all of the pilot holes in the left wing spar and moved on to work on the right wing spar. I setup the right spar and proceeded to drill all of the pilot holes at each of the rib stations.

I started by studying the plans to be sure that I understood the stack of spar webs. Next I realized that I could use the 0.090 thick spar webs to layout and drill all of the pilot holes in the various angles that go at the inboard edge of the spar. My plan is to open up the alignment holes to 3/16" in order to ensure that the root wing attache assemblies and end wing wing attach assemblies can be lined up using the current 3/16" hole that is in the attach blocks. To get to this point I overlapped the two 0.090 web spars and clecoed them using the wing attach holes and the center alignment holes. Next I drilled out the remaining alignment holes to #30. My intent here was to ensure the the attach holes were aligned (using clecos) and then end up with exceptional alignment of the intermediate holes by up drilling both at the same time. Next I inserted copper clecos in the intermediate holes and proceeded to up drill each of the remain three holes to #30 one at a time. After drilling to #30 I moved on to 3/16 for the wing attach points only. This will serve to align the wing attach blocks. Next I used the 090 spar web to pilot drill the first of the angles at the inboard end.

Today I continued to drill the pilot holes in the left wing spar.

I continued to drill the pilot holes in the left wing spar.

I completed the cleanup of the final spar cap. Now on to assembling the spars.

I worked at getting the left hand spar assembled. I fit the web and drilled a bunch of the pilot holes so that I could cleco the spar together.

Today I am continuing with the cleanup of the wing spars. I’m using a small half sheet sander, my sanding block and scotch brite. I completed the two lower spar caps. Next I’ll work on the upper spar caps. These I won’t be as fussy about the machined of flange. The plans allow it to be proud by up to one sixteenth so I’ll just focus on cleaning up the machined edges and getting rid of the scratches.

Wow, I completed one of the upper wing spar caps. They are a a lot of work. It takes a fair bit of elbow grease to get all of the small scratches out. Tomorrow I’ll work on the last spar cap. Then I’ll be ready to work on the spars themselves.

Tonight I continued on my clean up of the spar cap. I finished the work on the small 1/16 inch flange.