I’ve spent more time completing the Forward Spar Fitting and started work on the Main Spar Fitting SNX-T03-02
More Cutting And Filing Fittings
More cutting and filing away at the forward spar fitting.
Horizontal Stabilizer Fittings
I started working with the fittings made from angle. The first part I picked was the forward spar fitting. This is made from a piece of 2-1/2" x 2-1/2" x 3/16" angle that has to be cut down quite a bit. I started by cutting a length of angle down using my hacksaw. Next I marked up the first cuts and used my band saw. I need to get a proper blade as existing blade only has about 6 teeth per inch and wanders a fair bit. After cutting the angle I next used my files to clean up the cuts. Again, I discovered that I really need a vixen file.
Finished Forming The Last Of The Ribs
Today I finished forming the last of the ribs required for the elevator, ailerons, flaps and rudder. Here they are all layed out on the bench. The only thing remaining is the small joggle in the end ribs for the fiberglass tail tips.
Formed Long Bends On Flap And Aileron Ribs
The heading says it all. I will need to make up another short clamp bar for the bending brake to form the short flange on both ribs.
Deburring
I deburred all of the remaining ribs today. Now I just have to form them. I also ordered a set of offset seaming pliers to help form some of the sharp bends.
Layed Out And Cutout Remaining Ribs
Using the templates I made earlier in the week, I layed out the remaing aileron, flap and tail ribs and cut them out.
Templates For The Remaining Ribs
I drew up the remaining tail, aileron and flap ribs using AutoCad. I then plotted these out full scale and glued them to bristle board to be used as templates.
Completed Elevator Ribs T07-02/03
I finished cutting out two more elevator ribs and forming all of them. I also started to layout and cutout the elevator root ribs T07-04L/R.
Made New Clamp Bars For The Bending Brake
Today I purchased a couple of lengths of 3/8" x 2-1/2" cold finished flat bar from the Metal Supermarket. I had one piece cut to 15" long and I had one piece 30" long. From the 30" long piece I cut a 2-1/2" long piece. Next I ground a 10 degree angle along one edge. I finished the edge with a file and then put a 1/8" radius on the edge. The 3/8" clamp bar replaces the 1/2" that came with the brake. This allows me to form tighter bends when they are in the same direction as required for the elevator ribs. I also made sure that I radius the top edge so that it would not dig into the first flange when forming two tight 90 degree flanges.
Dave's Sonex Builders Log 
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