SonexBuilders.net

Like many people, I'm building a Sonex because it strikes the right balance between affordability and performance, with great emphasis on affordability. I'm doing a very basic panel and really like the Uavionix products. The TailbeaconX is a good /cheap way to be ADS-B compliant, which is especially important for me as I fly under a Mode C veil.

To use the TailbeaconX with the Sonex, I 3D printed an adaptor using carbon reinforced nylon and was able to get what I really think is a nice install. Here's a set of pics showing the process that I followed, starting with the finished product.



I should have sanded the 3D printed part prior to painting, but overall it looks pretty good.

After printing the adaptor, the next step was tracing a pattern and cutting a hole. I temporarily stuck the adaptor on the tail, and traced an outline.
It was pretty straightfoward to use my CAD program to create a template, and I aligned the outline to my trace. Next, I used a fine tooth saw to cut the fiberglass, drilling holes in the corner to prevent any issues.

A little test fit

Showing off the embedded threads.

I wasn't sure what color to paint my plane so I just did white primer. Like I said, I should have sanded first before painting. I think it's important to tape up the inside to prevent paint interfering with the epoxy.

If I was smart and planned ahead, I would not have added the fiberglass tip before running the wires. Using a janky boroscope, some luck, and lots of cursing, I was able to get plastic edge protectors through the 1/4" hole in the front leading edge and fish the wire through.

To prep for epoxying, I taped up the exterior of the tail and the adaptor, and cleaned the parts with alcohol. I made sure the threaded inserts were well taped! I also roughed the surface up with the grittiest sandpaper I had before the wipe.

I mixed up some West Marine slow curing epoxy and added flox until it had a paste consistency then generously applied to both parts. After aligning the pieces I used a tongue depressor to scrape up the excess and do some contouring. The thickness of the epoxy helped keep the part in place. Before it cured I removed the tape.

Sorry, not a lot of pics since I was focused on getting done before it all cured....

Lessons learned:
1. Best to do all this before completing the vertical stab
2. Sand the 3D printed part
3. make sure you test fit and add marks to show direction
4. Slow cure epoxy gives you plenty of time to work, and fret.
5. Epoxy gets everywhere. Cover up your parts with tape!

Nice job!

That mount for a TailbeaconX looks like a good idea. I have only recently acquired a 3d printer, just a cheap Ender3 and have yet to print any material other than PLA. Would you be able to provide files and printer settings I might be able to use to duplicate that mounting adapter? Unfortunately My vertical tail is already complete, so I would be fighting the same issues with routing the wires that you encountered.