Dave's Sonex Builders Log

To cutout the center of these doublers I drilled a 1/4" hole near the edge and then used a coping saw. It takes a while but it does work. I went through a couple of blades. In the end I found that an application of candle wax like I have been using on the band saw helps things along. I need to apply the wax several times. Once the parts were cut out I used a file for the straight edges and a sanding drum in the drill press for the curves. This cleaned things up nicely. I finished the edges with 220 grit sand paper and some scotch brite. For sanding the inside curves I wrap the sandpaper around a 1/2" socket extension. This seems to work well.

I made template for this part using my velum and cardboard. The template was then traced onto the aluminum sheet and cutout on the band saw. I used the bench sander bring the doubler to the final size.

I marked pilot holes and drilled all of the parts. Next I finished the parts by sanding and using scotch brite.

This was a fairly simple part. I measured, marked, cut, filed, sanded and scotch brited both in fairly short order.

Another simple pair of parts. I setup the fence on the band saw so that I could rip the spacer to the correct width. Next, I cut them to the correct length and filed and sanded the edges.

Again, I used the fence to cut a bunch of 1-1/2" pieces. Next, I filled the two finished edges and marked the remaining cuts. Using the band saw I finished cutting the pieces to size then used the bench sander and a file to finish the edges.

I finished cutting out the second part, filed and sanded it to size. Next I marked and drilled all of the pilot holes in both parts and then finished the parts with scotch brite.

I layed out and marked both parts then cut them out on the bandsaw. The usual filing, sanding and scotch brite finished the 07R and I started sanding the 11L. I stopped work on these parts at this point as I may alter the instrument panel. I’m working on an idea that will give me a little more room in the panel. While, it’s probably not required I just makes me feel better.

Today I started working on all of the 0.090" thick components. I started by tracing the attach plate onto velum and then glueing it to cardboard to make a template. Next, I traced the template and cut out two pieces. I finished one of these with a file and sand paper