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New drill bits did the job. On the troublesome axle, I ended up drilling from both sides towards the center, then line reamed the holes bigger with the 5/32" bit.



So here is the final set-up for the axle attachment.



And axles are attached. Drill the brake backing plate, attach the drum brake components, and the wheels can be bolted on.

Well it's a double post tonight...have to make up for going to bed early last night.

So, Bryan Cotton, this ones for you:

"ON THE GEAR IN (nearly) A YEAR!"







Up next:

Dual control yokes, rudder pedals and flap drive rod
Install horizontal and vertical tail surfaces
Rig controls
Complete Instrument Panel Layout and install instruments
Wiring

Locate firewall forward items for layout and attachment to the firewall
Complete final drilling and countersinking of engine mount hardware
Install engine
Make final decision on Turbo...

Awesome! You are redeemed.

No work for the last three nights, and I was getting grumpy as a result. Placed the horizontal stabilizer in place to see how it fits.



Made the jig to measure 25 degree up travel (or 160 degrees from the skin to outside of elevator skin). Not even close yet. I used a blue sharpie to outline the needed cuts on the lower skin so the horizontal stab will slide forward.

Clamped this in place for now, and figured what the heck, let's temporarily set the vert. Stab. These shots are purely for gratification and motivation to get back on track! Can't be slacking off for now three days and be done by spring!

Looks good Scott! Many times have I done work for gratification shots which had little practical value. Not so much on the Waiex but on the C140 and Hummelbird. I just put all my tail stuff away as I am done with tail mounting.

I understand the whole grumpy thing too. The time I spent in the hangar yesterday was to fix house things. The I got on a clean and organize kick, which is critical sometimes. Hope to get productive again tonight.

The horizontal stabilizer has been trimmed, and fitted, and trimmed some more, then Fitted again...
I was able to position the stab within Sonex spec, but still could not get the full up travel. As others have done I began minor relief griniding on the elevator control horn. After some consulting with. Mike Farley I called this close enough. I can still massage the control horn a little more to get that extra degree.



Clamped the horiz stab to the fuselage and transferred the mounting holes. First was 3/32", then updrilled through to the final size of 1/4". I sure like working in aluminum over the steel and titanium of the last few weeks.





Second trial fitting of. The vertical stabilizer. Still need to relieve and remove some of the turtledeck skin to get the forward mounting angle to fit.

Looks great Scott! You'll have those pieces done in no time!!

It's amazing how much more complete the airplane looks!

Big news, the back ordered MGL Xtreme arrived today! While waiting to find out when it was coming, I reached out to MGL and got to talk with Matt via email. He informed me the units that shipped this week are new and improved and have a brighter screen display that previous versions! Great news, and hopefully worth the wait. I am amazed at how small and light weight this device is.



Back to the airframe. The vertical stab is now drilled and bolted in place. I've been debating for the last few months about how to finish my Sonex. Paint or Polish, or a little of both? Decided to give polishing a fair shake and really go through the steps, fine tuning the process I was using. Watched Kerry's video again last night, and spent a few hours today working on the turtle deck. By gosh I think I have it figured out. The area closest to the vertical stab has received about 5-6 passes with the course grade, and two with the medium grade (I'm using Granitize product line instead of Nuvite). The rest of the turtle deck is about 4-5 passes.

What do you all think?







Don't you just love my apron? It's a remnant from when I built and owned my a Factory Five Cobra replica.

Here is what I'm thinking for a final paint/polish scheme:

Scott,
The polish looks good! Stick with it!

Scott,

As usual, you are an overachiever. That Polish looks amazing! Keep going!


Robbie Culver
Sonex 1517
Chicagoland
Tails and Wings complete - finishing fuselage.
N1517S reserved