Scott's Sonex 1629 - N629SX

[ScottM-Sonex1629]

More engine progress this weekend. All of the cylinders, cylinder heads and rocker arms and push rods are rimmed and adjusted and installed. Starting to clean up the small list of block off parts, oil pump, etc. all that's left of the main engine assembly is to set the rear shims and seal, the flywheel one last time...with the torqued down gland nut.

[MichaelFarley56]

Looking so cool Scott! You're basically done at this point...keep it up! Have you decided on a prop yet?

[ScottM-Sonex1629]

Mike:

I haven't decided on a prop or FWF stuff yet. Waiting to see if Sonex announces the Turbo kit at Airventure or sometime this year. That will change a few things with the engine...

[Sonerai13]

Hi Joe,

I will begin assembling my AeroVee in the near future, so these posts on that subject caught my attention.
The AeroVee assemble manual, REV U, calls for Permatex Aviation Form-A-Gasket #3 or Flange Sealant, but other posts here say the #3 is not up to the task. Shall I follow the assembly manual and hope for the best?

Terry

Hi Terry. I have never had a problem with Form-A-Gasket #3. That's what I use for the case halves, and for the cylinder bases, per the AeroVee manual. My best advice is to ALWAYS follow the manual. If you don't, then that word "EXPERIMENTAL" on the side of the airplane takes a greater meaning! :)

[Klimek]

Scott, this may be a little late, however could help.
I worked for V.W. for 23 years, many of those earlier years building air cooled engines of the type 1, type2, type 3 and type 4.
All the engine cases were sealed with V.W. case sealer. It came in a small can with blue or black writing with a brush. In a bind
I used Permatex #3 or aircraft grade sealers. If I can order this from a local dealer I will use it, if not the #3 aircraft grade will be used.
I do not remember ever having a case half joint leak. Also if you are concerned with the crank seal leaking, I ordered a genuine made
in Germany ELRING brand seal kit AND a special double lip main (crank) seal also by ELRING. All available on any V.W. racing or off
road / hi-perf part supply outlet. SCAT, EMPI, etc.
Hope this helps,
Frank

[ScottM-Sonex1629]

After essentially completing the engine assembly (just need to finish the ignition system install)...Mike F. stopped by this week and lent a hand to remove the engine from the rebuild stand. Now I need to finish the fuselage to have something's to hang the engine from!



So picking up where I left off...after a mystery illness that led to a "C" scare, outpatient surgery for a lymph node removal, and a subsequent staph infection that put me in the hospital for a few days last weekend...I'm finally starting to feel like myself again. The good news is my biopsy was negative for anything life threatening. The bad news is the infection and remaining swelling and scar on my neck.

THe little things in life like working on a hobby are a bit more rewarding now!

Like I was saying...it's been almost two months since I worked on the forward fuselage angles...so this weekend I decided to get back into it...slowly but made a lot of progress by end of the weekend.

Lower longerons (forward) are done. Upper longerons are both fabricated, drilled and slotted (left side). The technique has been done before, evenly spaced pilot holes updrilled to 5/32" then finished off the slot opening with the Drexel cut off wheel, a file and scotch brite pads on my angle grinder.









Just need to make the pheonolic sheet backer for the canopy latch slots and this piece will be done.

[Bryan Cotton]

Scott,
Glad you are recovered enough to get back at it!

[ScottM-Sonex1629]

Completed the upper left longeron, then moved onto sheet SNX-F14...the last sheet of angles for the forward side panels of the fuselage. Last night I measured and rough cut all required angles - 14 in total.



Tonight I was able to finish 4 of the 1"x1" angle parts and made two long rip cuts on SNX-F14-13R and 13L.

[MichaelFarley56]

I know I've said it Scott, but you're going to have a blast putting the forward fuselage together! Once you get all those angles done you'll be ready! They look great!

[ScottM-Sonex1629]

Another major milestone today. Finished all of the angles from sheets F13, F14, and F15 which means I could start the layout of the forward fuselage side panels.

My collection of completed angles (sheet F14) took about 10 hours to make all of these:


Right side panel dimensioned lay out:


Rough layout of the angles in position: