Ken's Sonex 1243

[Bryan Cotton]

Looks good Ken!

[Sonex1243]

Thanks Bryan. Got everything stored and on to the next phase of flaps and ailerons. The angles and cut outs look a little intimidating..

[Sonex1517]

Excellent! A big milestone! Congrats


Robbie Culver
Sonex 1517
Chicagoland
N1517S

[Bryan Cotton]

Ken,
The flaps and ailerons are pretty easy and fun to build. I would not worry about the cuts etc.

[Rynoth]

It's real easy to overthink the angled cuts on the aileron and flap skins. I even tried to make them with my miter saw using trigonometry to dial in the various angles. Don't do this.

Just mark each measurement as it is on the plans (paying attention to which side is "up" and which side is "flat"), draw a line between the marks, and use a cutoff wheel or snips to make the cuts.

If you want to give yourself some room to breathe, make the angled cuts first, before cutting the far side to appropriate length. That way if you muck up the angled cuts, you can just move down the aileron an inch and try it again. Just draw your line for the straight cut, use that line as reference to make the angled marks, and cut the angle side first.

[Sonex1243]

You guys were right!
I managed to get the flap angles cut on both and then trimmed to final length. I had made the drive horns and hinges awhile back, so, they should go together as pairs pretty quick.


Left flap marked and right flap cut, trimmed and marked for pilot drilling


Fitting right flap drive horn


Both flaps trimmed and cut to final length with rib / drive horn fitting in work

[Sonex1243]

Flaps ready for deburring and the dreaded polishing. I think I'll get the ailerons ready and polish everything then.


Right flap piloted


Left flap piloting in work


Flaps piloted


Ready for deburring

[Sonex1243]

Work continues with the aileron counterbalances. The drive horns and hinges were done a while ago.

my demented way of aligning and pilot drilling the ribs to the arms

ready for riveting

finished

[Sonex1243]

After some slight confusion on an aileron skin dimension, I finished cutting the skins and made the other cut outs for the drive horn and counterbalance assembly. Started marking the rib locations and only have the right one down to marking the rivets.


skins cut and filed


tip cutouts done


right skin rib and rivet locations in work

[Sonex1243]

Didn't like my first round of markings, so, I erased them and re-drew. Much better this time. Got the right aileron skin piloted and have the ribs and counterbalance assy in place for piloting.


Skin piloted and ready to pilot the ribs etc.

A rare glimpse of the dungeon, was a warm day last week and had the door open. Natural light for once was a treat. Now, to actually do some cleaning and rearranging some day..