Ken's Sonex 1243

[Sonex1243]

Despite the sub zero ambient temps and a -22+ wind chills outside, I managed to survive in the garage this weekend by keeping it around 40* with the Mr heat big buddy propane radiant heater and two electric heaters on low! Got the wing frame completely deburred except the bottoms of the main spar, I ended up breaking the in/out deburring tool due to a lapse in attention. There goes $50.00! Deburred the wing walk doubler and the flap and aileron hinges. Started the leading edge and have it about 1/2 way done.


So much left to do!

[Sonex1243]

Moving along still. All the deburring, edge finishing and cleaning all done. Built and fit the duck works LED light mount for the rib bay. All the skins are ready for polish before riveting begins. Still need to run the wiring and conduit through the forward ribs.

[Sonex1517]

Excellent progress.

This spat of frigid air in Chicagoland leaves me happy not to spending another winter in the garage building.


Robbie Culver
Sonex 1517
Chicagoland
N1517S

[Sonex1243]

Aft skins complete with 3 passes of F9. Forward skin half done with F9. One pass of "C" is next on all of them before they are eventually riveted.


Upper skin


Forward skin

This polishing business is getting to be a workout!

[Rynoth]

Nice Ken! Yea the polish before riveting can be a real test of patience when you're so close to making a finished wing, but believe me it's totally worth it in the long run.

[Sonex1243]

Thanks Ryan.
I forgot to mention that I will need to take care of some dings in the upper skin from some (hasty / stupid) mis-handling during flipping that caused clecoes to drag. I reversed a set of sonex dimple dies and that seemed to help a lot in removing the small ripple, but, the rivet head will not conceal the marks completely.. I also have to contend with 2 small kinks in the forward skin, once again, due to my in-attention while handling them as well...

Is there a way to try and roll them out with like a spoon or something?

[Sonex1243]

Forward skin F9 finished. Forgot to clean the "C" pad and rags from the right wing, so, a slight delay while I clean the buffing pad and rags..

[Bryan Cotton]

Looks good Ken! I hope to get to F9 on the LE skin tomorrow.

[Sonex1243]

Thanks Bryan;
Finished the forward skin with one pass of "C" and dimpled for the flush rivets. Also finished the lower skin pass with "C". Have the upper skin ready, but, we are going out of town for the weekend. A little break will be nice.

[Sonex1243]

Major accomplishment, left wing is completed!


Upper skin installed

Control rods installed

Duckworks light installed

Lower skin installed. Forward bottom installed

Forward skin installed