Dave's Sonex Builders Log

Today I finished the sanding of the fitting. I trimmed the ends to length and then I formed the 35 degree angle. I used the traditional dowel and vise forming process. Have a look at the pictures to see what I mean. I think the part turned out pretty good. There was a little orange peel around the bend but a scotch brite pad cleaned that up nicely. I should mention that you have to overbend the part and then release it to get the correct angle.

I took one of the strips that I had previouly ripped to width in my band saw as a starting point for this part. I cleaned up one side using the vixen file. My long straight edge was helpful in ensuring that the edge remained straight as I filed. After filing and sanding I setup the band saw and trimed the strip again to get closer to the 2-1/4" width. Next, I filed the other side of the part to get the final width. I squared up one end and then marked the cut for the finished length.

Tonight I cut the slot in the fitting. Then I started filling and sanding the slot to the finished size.

I check the large end of the fitting to see that it was appropriately square with the centerline and then proceeded to file and sand the sides of the part. The next step is to cutout the slot in the fitting.

I finished cutting out the strips of Aluminum and also rough cut out the SNX-T12-07