Dave's Sonex Builders Log

Today I finished the layout of the first web, cut it out and then did the same with the second one.

I started the layout of the main spar center web. To begin with I cleaned up the top and bottom edges with the vixen file and sanded until I had two straight edges that I could work from.

These were a bit fiddley(sp). I ripped a strip of aluminum to 1/2" then filed one edge flat and added the radius to the other long edge. Next I setup my fence in the bandsaw to 5/8" and cut out all of the blocks. Finally, I sanded the fresh cut edges. I think I have all of the 1/8" parts complete except for the inner spar webs.

I added the rad to the bottom edge of the doublers. I forgot these when I originally made the parts so I had to go back.

Marked and cut out both doublers on the bandsaw. I dilled a starter hole and used a copping saw to cut out the large hole in the doubler. Next I used a sanding drum in the drill to finish the hole. I filled and sanded the edges then marked and drilled the pilot holes.

Drilled the holes and cleaned up with scotch brite.