Finished making W04-07
Counter Balance Plates
I started each of the four plates by cutting a length of 0.090 aluminum from the strips I had previously ripped on the band saw. Next, I filed the two long edges to get 3-3/8" inches. With this done I simply measured and marked the remaining cuts. These were then cut on the band saw. I filed and sanded the edges to get the final outside shape. Once all four were ready I started to layout the 3/32" pilot holes for the rivets. This was straight forward and I drilled most of the holes in the drill press.
Spacer
These were very simple rectangular spacer. I used my fence and ripped the two pieces to the correct width then cut them to length. A quick file and sanding of the edges finished the parts
Aileron Drive Plates
These were two simple parts also. I layed these out directly from measurements onto the aluminum. Cut the pieces to size on the band saw and rounded the tip using the bench sander. Next I filed and sand the edges. I marked all of the pilot holes and setup a fence on the drill press for 1/4" as this is the edge distance for the holes. Next, I drilled all of the holes. I left the 3/16" hole for later but pilot drilled it 3/32" for now. I finished the parts using scotch brite.
Seat Belt Gusset Plate
These were fairly simple gussets. I measured and layed these out directly on the aluminum. Cut the parts on the band saw and filed and sanded the edges. Marked and drilled the pilot holes and then applied scotch brite.
Shear Plates
Again, these were simple parts that were layed out, cut, filed and sanded and the marked and drilled.
Doubler
I finished both doublers with scotch brite.
Lower Gear Gusset Plate
I made templates for the gusset plate then traced it onto the aluminum. Cut the aluminum on the band saw and then sanded the part using both the bench sander and a sanding drum in the drill press. I finished the edges with a file and 220 grit sand paper. Next I marked and drilled the pilot holes and then finished the part with scotch brite.
Upper Gear Gusset Plate
These were made in a maner similar to the low gear gusset plates.
Doubler
Today I makred and drilled the pilot holes on both doublers.
Dave's Sonex Builders Log 
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