SonexBuilders.net

Hello all,
I am currently away from home now, so away from my plans, and trying to get the materials I will need to move ahead when I get home. Can you tell me what material the fuel filler box is made of? Is it stainless steel sheet, or aluminum? If it is stainless steel sheet, does Sonex sell the precut or preformed parts for this, or at least the material to make it?
Thanks

It's made from 0.016 thick 301 Stainless Steel - 1/2 hard....and yes, Sonex does sell the precut parts for this.

I made mine from scratch, and in all honesty it was one of the harder parts that I had to make, (in effort, not skill as cutting and filing the SS is very difficult), but in the end it came real good. So build or buy is really up to you.

Note: One 4x4 sheet was enough to build all the SS parts for the aircraft. If you are only looking for the fuel filler box (and not the Firewall, etc) then you'd probably be better off getting it from Sonex.

If I was scratch building my firewall parts would be Ti. Just as hard to work with but lighter.
http://www.titaniumjoe.com
Very common in helicopters and high end machines.

I am doing a lot of scratch building combined with buying parts from sonex that I think are easier and better from them.
The SS fuel filler box was one of them. Also be carefull to do the bends accuratly, otherwise to box won't mate to the opening
in the upper fire wall well.

Scratch builder here also...

It is one of the more difficult and time consuming pieces to make. The SS is super sharp, guarantee to leave you with a few cuts. If you are combining scratch and sonex components, if you aren't diehard on making it... Buy it. Also, layout all the pieces first before cutting. If you cut the upper wall before laying out the top piece you may short yourself. I did by 1/2 inch, luckily it didn't affect the overall finish.

vicdelgado9 wrote:Hello all,
I am currently away from home now, so away from my plans, and trying to get the materials I will need to move ahead when I get home. Can you tell me what material the fuel filler box is made of? Is it stainless steel sheet, or aluminum? If it is stainless steel sheet, does Sonex sell the precut or preformed parts for this, or at least the material to make it?
Thanks

Stainless. I don't remember the making of the parts being difficult, but I DO HATE drilling STAINLESS! My tricks: small diameter cobalt bits for a pilot hole; snap the bases off so the chuck WAY down inside your drill (leave only 1/4" exposed outside the chuck); SUPER SLOW speed on the drill (like one rotation every 2 seconds); LOTS of pressure. The short bits help keep the things from snapping under the pressure. After the pilot hole you can updrill. Still super slow speed + much pressure, but after the pilot hole things will go fine.

http://www.mykitlog.com/users/display_l ... 279&row=75
http://www.mykitlog.com/users/display_l ... 330&row=74
http://www.mykitlog.com/users/display_l ... 403&row=72
http://www.mykitlog.com/users/display_l ... 734&row=66
http://www.mykitlog.com/users/display_l ... 296&row=62
http://www.mykitlog.com/users/display_l ... 417&row=61
http://www.mykitlog.com/users/display_l ... 459&row=60

Mike Smith
N439M
Plans-built

mike.smith wrote:

vicdelgado9 wrote:Hello all,
I am currently away from home now, so away from my plans, and trying to get the materials I will need to move ahead when I get home. Can you tell me what material the fuel filler box is made of? Is it stainless steel sheet, or aluminum? If it is stainless steel sheet, does Sonex sell the precut or preformed parts for this, or at least the material to make it?
Thanks

Stainless. I don't remember the making of the parts being difficult, but I DO HATE drilling STAINLESS! My tricks: small diameter cobalt bits for a pilot hole; snap the bases off so the chuck WAY down inside your drill (leave only 1/4" exposed outside the chuck); SUPER SLOW speed on the drill (like one rotation every 2 seconds); LOTS of pressure. The short bits help keep the things from snapping under the pressure. After the pilot hole you can updrill. Still super slow speed + much pressure, but after the pilot hole things will go fine.

http://www.mykitlog.com/users/display_l ... 279&row=75
http://www.mykitlog.com/users/display_l ... 330&row=74
http://www.mykitlog.com/users/display_l ... 403&row=72
http://www.mykitlog.com/users/display_l ... 734&row=66
http://www.mykitlog.com/users/display_l ... 296&row=62
http://www.mykitlog.com/users/display_l ... 417&row=61
http://www.mykitlog.com/users/display_l ... 459&row=60

Mike Smith
N439M
Plans-built

That's what I found as well (I believe I mentioned it here before), I just don't remember cutting/bending the stainless to be that much more difficult than working with aluminium.
Drilling SS however, what a PITA that is! Still wake up screaming at night sometimes :-).

That is one of the parts I scratch built for my kit, as I wanted to make one that included a catch trough across the bottom, with drain. SS is actually quite easy to work with. and more malleable and less prone to cracking than hard 6061-T6 aluminum. Just use slow drill with lots of pressure, and good sharp shears. The thin gauge can make nasty cuts, so some care is needed.

David A.

DCASonex wrote:That is one of the parts I scratch built for my kit, as I wanted to make one that included a catch trough across the bottom, with drain.

David A.

I did the same. The thought of spilled fuel running directly into my cockpit just seemed utterly insane to me. With only 50+ hours, that catch pan has already caught 5 or 6 spills.

Mike Smith

Can you provide a sketch or photos sowing the trough? Sounds like a great idea.