Ken's Sonex 1243

[Sonex1243]

In between RC flying, relatives visiting and glider towing, I managed to get the fuse side details done. Cut the 4" access holes with a fly cutter in the cordless drill, cut the rudder cable openings and fabricated the rudder stops. Also completed the 14 degree bends on the forward end on both sides. Hopefully get the longerons completed n the near future.


Pile of parts


Rough cutout


Finished hole with practice piece


Finished side

[Sonex1243]

After some more distractions, I finished the longerons, pilot drilled to both sides and clecoed the vertical channels in. Match drilled the rudder stop plates, dug out the splice plates, cleaned them up and hopefully get the bevels and bends done. I always have difficulty making an opposite piece..


Left side longerons in work


Both sides piloted for now

I am beginning to think about space at this point, once the panels are polished and riveted, I will probably stop there and do the forward sides. Reason being that once the aft fuse box and cross tie framing is started, I will be out of table space to build anything else!

[Sonex1243]

Bathroom remodel project to begin very soon. Stopped the fuse sides so I can break it all down since I now need the garage space to store all the remodeling supplies and fixtures. Started some smaller projects like the aft shear web and the shoulder harness attach assemblies. Have also been flying a lot of chase plane for a herme's 450 UAS that is being used for ag research.


Aft shear web


Everything laid out for shoulder harness assy's


Ready to upsize, clean and rivet


Herme's 450 in flight

[Sonex1243]

Short trip to KOSH complete! Great time at the Sonex BBQ. Met several folks and a thanks to our host for accommodating the group. Short build spurt, riveted the shoulder harness attach webs.

[Sonex1243]

Post KOSH spurt. Cleco'd the cross tie box together, after I finally figured out the extra holes match drilled on the upper flange of the forward channel, they are for the upper horizontal splice plate. Match drilled them to #40 only on each end. Upsized everything else to #30 and then took it all apart for deburring, edge finishing and riveting.


upper web upsized with splice plate attach area piloted


lower web upsized


debur me please...

[Bryan Cotton]

Ken,
Many of us have riveted the bottom of the box on first. Then we drilled out all the rivets and put the top on. The bottom goes on when you have bolted up the splice plates for keep and deburred the seat hinge holes. No need to take that extra step, I am sure it would be fine if you did it right the first time.

[Sonex1243]

I had heard and read about the bottom web being installed from several build logs. I initially would have done the same thing if it wasn't for that, the plans drawing could be misinterpreted easily except for the side view that showed rivet placement! I could sure use a good spurt of getting it right the first time :?

[Sonex1243]

Cross tie box completed. A delay is now in order, after two days of reorganizing, the renovation supplies arrived and have been stored in the garage and on the build table. The good news is I still have some table space left, probably focus on a lot of smaller sub-assemblies and channel edge cleanups while this is going on for some time.

[Sonex1243]

I am slowly getting back into the build, finally after remodeling and a few other distractions.. I did manage to get all the match hole, machine angle and some smaller pieces from plans page SNX-F27 through SNX-F21 edge finished. Really feels like no headway, but, these are the pages for the entire rear fuse, except the turtle deck, that were cleaned and prepped for fitting and drilling.


Pile of parts waiting to be assembled after I dig the aft side panels and longerons out again

[Sonex1243]

It is amazing how easy it is to fall off the "building" wagon. Starting the forward fuselage sheets since it dawned on me that once the aft fuse is all boxed on the table, I would have no space left to build the fwd side panels. Eased my way back into it, started the flap drive blocks and rudder pedal support brackets.