Discussion with Sonex about Spar Box Construction

[N418SX]

I had a discussion yesterday with Sonex about the construction of the fuse spar box. The donated/purchased kit we are currently working on has a fuselage that was partly constructed, included in that construction. My question was what kind of rivet device do you use inside the spar box as it is too tight for anything we currently own. The reply was that the spar box is not built until the wings are mounted, jigged and aligned. We have reviewed the plans and we need some advice. what do we need to remove?

[Area 51%]

If it's a Legacy you're working on, go to page F-12. The aft verticals and everything that attaches them, that shouldn't be riveted till wing rigging, have an X through the holes.

The F16-03 tunnel web needs to be removable as well. As soon as you decide on your gear configuration, you can rivet the attachments to that web. Everything except the verticals that is. The print has you holding off till the last minute in case you change your mind about the gear, I guess.

[N418SX]

Gear is conventional.

[Area 51%]

Then you can go to page F01 view A-A and ignore the left-hand side of that view. View B gives the rivet pattern for the standard gear. The support angle across the top and the small vertical angles (that support the control sticks) can then be riveted in place keeping in mind the outer holes don't get rivets till wing rigging.

Make sure ALL the holes have been prepped before riveting anything together!! It doesn't look like your support angle and vertical angles have been properly drilled yet.

[sonex892.]

I used a hand rivet squeezer inside the tunnel. I do remember the bottom couple of rivets were the most difficult. I probably used a wedge with a hole to squeeze them.

Here is is a photo taken during rigging. You can see what parts of the tunnel need to not be there before up drilling the front 2 holes. The floor not being there at this stage is optional.

[N418SX]

So this is what I have come up with so far that required removal. Comments welcome.

[Area 51%]

If those aft verticals are already riveted to the fuselage, they will have to come out.

[N418SX]

If those aft verticals are already riveted to the fuselage, they will have to come out.

Rear only, correct?

[Area 51%]

Correct. To be clear...we are talking about a "Legacy" model....right?

It's my understanding the Bs are the opposite.

[N418SX]

Correct. It is a legacy.