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I'm enjoying my Sonex a lot, but since I didn't build it I don't have any spare hardware "left over." For regular maintenance I'm sure I'll need to have a supply of cotter pins, Nylock nuts, gaskets, safety wire, and other expendable items. I can go through the plans and identify these, but wanted to see if anyone knows of an already existing list. I suppose I should also compile a list of the lubricants, thread sealants, and other magic chemicals needed to keep a plane airworthy. Some of this stuff is just easier and better to have on hand than to order onesies-and-twosies from Acft Spruce or make dozens of trips to the auto parts store.

Any inputs are welcome. If not, I'll come up with a first-guess and ask for comments.

Thanks,

Mark W.

Hello Mark,

Great question! I'll have to think about it for a little while to make sure I remember most stuff, but overall things really aren't too bad. There's nothing really special with the Sonex or the AeroVee that really requires a lot of special tools and parts. Unfortunately, I don't know if anyone has gone through and done a "maintenance sheet" list of items you'll need, but I'll try to write down a few things I normally use on my plane:

Tools:
- air compressor for tires (small ones are fine)
- torque wrench. Doesn't have to be a good one but you'll need to check your prop bolts with one. Most wood props have torques of around 10-12 ft/lbs.
- supply of regular and Phillips screwdrivers.
- supply of wreches. Lots of 3/8" and 7/16", but a normal set should be fine. Also, metric ones for the engine. Lots of metric hardware on the AeroVee.
- Allen Keys. I think the needle valve on the AeroInjector takes a 3/16" Allen key to adjust, but don't remember for sure. A standard set should be fine.
- Feeler Gauges. You'll need them to set the 0.06" valve lash on the vales of your engine.
- Cleaning Supplies. Polishes, window cleaners, and lots of microfiber rags for cleaning and polishing!

Sonex Parts/Hardware:
- Supply of AN-3, -4, -5 nylock bolts. You really shouldn't need many other than the occasional -5 sizes for the prop if you take it off, but those are always nice to have around.
- AN-3, -4, -5 bolts. Again, you really shouldn't need any at this point unless you're going to modify something, but having a few of various sizes never hurts. While you're at it, a few varios lengths of the AN525 screws are always nice. They may be needed on the wheel pants, cowling, etc, depending on how your plane was built.
- Cotter pins. Same thing...hopefully you won't need many but alway nice to have a few laying around. My advice is to look at the plans and determine which size of cotter pins you need for the control surfaces and linkages (the cotter pins holding the hinge pins in place as well as the cotter pins for the
AN-3 castle nuts at the end of most control rods), as well as the size pins for the landing gear axle nuts. Eventually you'll pull the wheels for brake replacement/tire replacement and you'll need those pins.

AeroVee Parts
Shouldn't be a whole lot here unless you need to perform repairs. The tools we've already talked about but to add to the list:
- VW oil change kit/gasket set. Sonex sells these or you can pick them up for the local auto parts store. Just tell them you have an old Beetle and need the oil change gasket kit. Should be a few dollars and contain two round gaskets, one big brass washer, and six small ones. You'll need one when you change the oil and clean the oil screen.
- VW head cover gaskets. I've re-used mine tons but if you are ever taking the valve covers off to perform a head bolt torque/valve adjustment, you may need a replacement set. They're normally cork and also cheap.

I hate to say it, but that's really about all I can think of right off the top of my head. As you can see, a basic set of tools (American and Metric) will pretty much take care of 99% of repairs and work. I'll keep thinking to see if I can come up with anything else.

Thanks,

Mike

Mike,
Thanks, that's a great start and I'm sure covers most of the bases. I'll paw through the plans and hardware lists for the hardware sizes (cotter pins, etc). I'll add items here as I think of them, then make a comprehensive list when it seems the ideas have stopped. Some minor additions to the items already mentioned:

Chemicals, etc:
- Engine oil
- Anti-seize Compound (Permatex Item 81343 or similar)-- For spark plugs, etc
- Thread sealant (for oil lines, etc)--Loctite Thread Sealant PST Stick Item 37615 or similar.
- Loctite Threadlocker (blue and red)
- Brake fluid (if reqd)
- Bearing grease
- White lithium grease (squeeze tube)
- Cleaning supplies (windscreen, canopy, polished aluminum, painted surfaces)

Tools
- Spark plug gap adjusting tool
- Crimping tool for electrical connectors (some folks can reportedly get reliable connections using regular pliers, the crimper on regular wire strippers, etc. I haven't been so lucky and am ready to buy a ratcheting crimper)
- Volt/Ohm Meter

Electrical supplies
- An assortment of typical connectors

Engine
- Spark plugs
- Extra crush washers for spark plugs