Dave's Sonex Builders Log

Today I made up support blocks (tools) to support the canopy while trimming. I saw the concept in the EAA video showing how to trim a sonex canopy. I used the original patter than I used for the turtle deck. I traced two blocks onto a piece of MDF. After trimming the blocks on the bandsaw, I worked on the profile which changes from the bottom to the top.

Today I up drilled all of the holes in the windshield to #30. Next I removed the windshield and used my microstop to drill the counter sinks for counter sunk washers on the leading and trailing edge of the windshield. After drill the counter sings I up drilled to 11/64 inches. I updrilled after as my counter sink has a #30 pilot. Next I dimpled the fuselage sides and then reset the microstop and countersunk the holes in both sides of the windshield and then updrilled to 11/64. After all the drilling I refit the windshield. I needed to up drill the rear gap filler strip to 11/164 as well. I all seemed to fit will together. The next step will be drilling and tapping the windshield bow.

I started by fitting the windshield to see if any trimming was necessary before drilling. I noted that the front corner was still too long. After trimming if refit the windshield and drilled the pilot holes down each side. I also marked the front corners towards the cowling that still needed some trimming. After completing the trimming I fit the windshield again. This time I only needed to use clecos to secure it. Next I drilled the hole through at the front edge of the fire wall. Now I need to figure out the dimpling. I drilled some test strips and have now set up the micro stop to work with both counter sunk washer and my own dimples. I found that I could put the washers in the dimpler just to guarantee they were the same as my dimples in the skin.

Today I finished up the pilot drilling for the windshield to the bow. Next I need to form the fuselage sides in to meet the windshield

Yesterday I trimmed the sides of the windshield. They are pretty close but the final fit depends on my front to back positioning and I am trying to leave a little adjustment for later. Today I started by trimming the front edge to allow the clecos to be inserted in the firewall to windshield Al strip. After marking the 1 inch reveal I worked at the rear end to measure and fit the bow strap.