Dave's Sonex Builders Log

I finished filing the edges of the first attach plate then layout and cut the second one. Again, I filed and sanded the eddges. Next, I marked the holes on one of the parts then clamped them together for drilling. After getting a few holes drilled I used some colecos to hold the parts together while completing the drilling. Next, I marked the tangent lines and bent the parts to 30 degrees. I found that by overbending to 33 degrees I was able to get the parts exactly 30 degrees after spring back. I finished the parts with some scotch brite to remove the orange peel marks in the area of the bend

I finished the support plates today by sanding and filling them to size then drilling the pilot holes.

I filled and sanded the edges of the splice plate to the finished shap then marked and drilled the pilot holes.

Again, I decided to lay these out by measuring the drawing instead of creating a template. After all the measuring for the first part I cut it out on the band saw. Next I started sanding in the 1 inch radius.

I started this the support plate by making a template. I traced the part onto drafting paper then glued it to some bristol board and cut it out. I traced out 2 parts and cut them out on the band saw. Next I sanded them using a small sanding drum in the drill press.

I cutout the second doubler and sanded it. Next I drilled the pilot holes and then scotch brited both parts

I cut out the first longeron doubler and sanded it.

I cut, filled, sanded and drilled the trim lever. I still haven’t sorted out the exact drill sizes for AN3 and AN4 hardware yet so I stuck with pilot holes for the time being. I also put the first two bends into the lever. These are the ones that look like a joggle at the bottom where the cable attaches.