Dave's Sonex Builders Log

I started the work today by cleaning up the rib blanks I cut out earlier. I used my bench sander as well as a sanding block and files to get all of the rib blanks to the same size. (Or as close as I could get) After making all of the blanks the same size I set up my bending brake and formed all of the flanges. Three of the ribs needed to be made left hand and three right hand. After forming the first three ribs I had to transfer the bend lines to the back side of the remaining blanks so that they could be formed in the opposite direction. I then formed all of the flanges. Next, I used my scotchbrite to clean up all of the ribs.

I deburred the hinges and then wrapped up the flaps for storage until I can get them inspected. Now on to the Ailerons.

Time to start laying out the 6 Aileron Ribs that I need. After tracing out the ribs, I cut them out with the Malco snips. Next I marked and drilled the holes for the radii at the flanges. Finally, I trimmed the ribs to size.

After removing all of the clecos and labeling the inner ribs I proceeded to deburr the ribs. The outside was easy using my swivel deburring tool but the inside of the flanges was more difficult. I used some 220 grit Al oxide sandpaper on a popsicle stick to break the burrs off from the edges of the rivet holes. Next I used a scotchbrite pad so finish the ribs. With the ribs completed I proceeded to use a block of wood to hold the flap skin open to provide access to the inside. Again, I used the w220 grit Al oxide sandpaper on the popsicle stick to break the burrs off the edges of the rivet holes. With the skin deburred I reassemble the flap using clecos and started the riveting. Again, I left the flap such that it could be opened for inspection.

I started by getting the pilot holes layed out on the hinge. Next, I drilled the pilot holes in the hinge and then transferred the holes to the flap skin. The next step was to enlarge the holes to #30. Next time I\’ll take everything apart and start deburring.

Today I started by deburring all of the edges on the flap skin. Next I pulled the rivets on two sides leaving a flap open for inspection prior to closing. After completing the right flap I started to layout the holes in the left flap. I matched the same mistake I made on the right side in order to ensure the two flaps look the same. After marking all the holes I drilled all the #40 pilot holes through the skin and then I started to install the ribs and complete the pilot holes into the ribs.

Today I started increasing the size of the holes in the right hand flap from #40 to #30. I used my soldering iron to cut away the protective film around all of the rivet holes leaving the rest of the skin protected. It worked well. Next I started to deburr the holes. I completed the first pass on deburring the skin moved on to the ribs.

Tonight I am continuing with transferring the pilot holes in the hinge to the flap skin. After completing the hinge holes I cut the mating hinge piece to length

I started today by making up the hinge for the right hand flap I was drilling yesterday. I marked and drilled all of the pilot holes in the hinge. I discovered that I made a mistake when I placed the ribs inside the flaps and they are off by 1/4 of an inch so I needed to adjust a couple of holes in the hinge to line up with the ribs. I left these for later. After drilling the pilot holes I started working on attaching the hinge to the flaps by transfering the pilot holes in the hinge to the flap. Complete the holes between the inboard rib and the next one out. I continued drilling the pilot holes for the hinge after dinner and managed to get the holes 2/3 complete.

Continued transferring the holes in the flap skin to the ribs. I\’m supporting the flap skin on a couple of 2x6s to provide room for the clecos to protrude down. The best sequence seems to be to insert the rib, clamp it in place using a spring clamp and then drill the holes in the narrowest (front facing) edge. After I get the first four holes drilled in the front edge I switch to either the top and the bottom. I\’m not drilling the holes for the hinge at this time although I have marked the hole position at each rib. I complete all of the #40 holes for the ribs. Next time I\’ll start on the left flap.