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Managed to close the gaps a lot better with some clamping combinations. Flipped the fuselage right side up and finished the upper splice plates. Took a time out and did an aggressive vacuum of the garage and fuselage that I have neglected all winter. Since I have 1/8" clecos left, I reinstalled all the sub floor channels and idler assembly to finish drilling and upsizing.

I will have a fitment problem with the F10-02 cap assembly and F15-12 angle clips, seems I too managed to get the placement of the clips a little high during the side panel build up as the corners are not flush with the bottom skin when placed into position. Quickest fix would be to just replace the angle clips and match drill in from the side panel holes. My collection of boogered parts continues to increase..




The 02 assembly piloting needs to be finished before upsizing


Most of the piloting done, a bit more to go and then upsize for deburring

Looks good Ken! Love the polish. Saw your reply on my Waiex thread. The golf cart will live again. Needs a piston and cylinder, and I found a new one on eBay.

All the upsizing is now complete for the fuselage box assembly and aft lower cabin detail installation plans pages. The countersinking, dimpling and deburring is all that remains. I decided to dismantle a little at a time for deburring and cleaning. First up was the removal of the cabin detail assemblies for deburr etc.

I also feel like I may have another polishing fever, but, it would only be the bottoms at the F3 stage..

Big post with lots of progress. Finished deburring, dimpling, countersinking and cleaning. Flipped back upside down and riveted everything together. Installed and riveted the lower cabin detail assembly I had riveted earlier. Started the seat install.









I am going to have to do something soon as far as an engine mount. I would really like to get the gear on and off the saw horses!

Looking great Ken. Subscribed to follow the progress.

Welcome to Sonex builders forum Davion. There is a lot of great information and support here.

Flipped back over and the seat install has been finished since the last post.

Spring cleaning is in the ND air! Pulled everything out of the garage for a LOT of cleaning and rearranging. Since I don't have an engine mount due to engine choice change, I made a few dollies and converted it into a low rider for now. I have been getting a lot less time on the project due to an annual AND engine change / prop overhaul on our Sierra. I did get the flap / trim mount installed on the left side and built up the rear spar carry through assembly. Just need to deburr, edge treat, clean and reassemble.







More distractions to come as the glider season is starting and I will be doing a lot of towing this summer.

Good progress Ken. Looking back, I'd add some reinforcement to the seat at this point. Maybe a simple doubler on the seat bottom. I think it should be stiffer.

Finally back at it again, off and on, after a lot of distractions with the Sierra and summer/work in general.

Managed to finish up the flap handle/tube installations as well as the rudder pedals. Took a lot of off and on to get the phenolic blocks reamed for a smooth control feel. Also completed the dual stick control colum, spent a lot of time getting the sticks drilled to the horns. started on the instrument panel and glare shield as far as getting them in place, haven't drilled anything yet as I am waiting for the fuselage to be right side up again.

The new engine mount arrived, I decided to switch to the 3300 Jab for an engine choice. That has held up the gear installation. I have been learning the hard knocks of drilling the blasted Ti gear legs, buggered up the mount end holes on both legs even after watching the EAA video Kerry put out! Good news is that I will just swap ends and re-drill as the wheel axle end holes are above the bad holes and won't be a problem per Sonex tech. I disbanded the Ti drilling and will work on getting the engine mount installed while I research other idea's and get my nerve back on drilling Ti...

Drilling set up


Crappy holes!

Hi Ken,

Could you explain a little about what you did wrong in drilling the TI legs? I have that out in front of me and would like to learn what to do and not to do. I cannot tell from your pictures.

Your project looks great btw. I am now starting on the seat area. Did you reinforce the seat bottom? If so, what did you do?

Rick Caldwell
Xenos 0057