Ken's Sonex 1243

[Sonex1243]

Spent some time away from the Sonex while doing the annual on our beech sierra. Since the Sierra was almost done, I got a quick Sonex fix today by modding the left O/B wing ribs for the duckworks LED light. Also cleco'd the rear spar in place, the wing is ready for up sizing to #30.

[Sonex1243]

Wing has been upsized. Since then, everything has been finally deburred, edge finished and cleaned up. I also went over the main spar again to clean it up and remove some dings from all the handling. Will start riveting the ribs and rear spar soon.

[Sonex1243]

Happy holidays everyone. Maybe the elves will visit tonight and tomorrow morning the skins will be on?

[Sonex1243]

A mysterious elf showed up over the weekend. Upper and lower skins fit, starting the forward skin.

[Bryan Cotton]

Looks good Ken. If your mysterious elf does fiberglass please send him my way. I hate the stuff!

[Sonex1243]

Thanks Bryan;
I am not looking forward to my turn with that stuff. I made a feeble attempt at the right wing tip and got frustrated pretty quick after notching and trimming. I tried to fit it with the aft tip flange on and induced a few broken chips, only after researching the Sonex site I found the wing tip instructions telling you to remove the flange..

[Sonex1243]

Leading edge in work, upper side pilot drilled, flipped it over and started the lower side.

After much delay, I finally bit the bullet and fabricated a support stand. I got the idea from Carl Ortons build site, who also encountered the wing constantly slipping off the support blocks. I kept the angles and heights exactly the same and the wing fits real nice in the cradle. Why didn't I do this with the right wing?? Thanks for the help and idea Carl.

I should be farther along, but, went flying and did some approaches for instrument currency today, beautiful weather today (unusual for ND) to do it.

[Sonex1243]

Finished up sizing the rest of the wing skins and doubler to #30. Drilled the forward skin and ribs to #32 for dimpling.

Dis-assembly in work


Cleaned up the shop, ready for deburring

[Bryan Cotton]

Boy are we neck and neck or what.

[Sonex1243]

I guess so Bryan! I think you have the upper hand with extra deburring / polishing power. The skins should go quick like the right wing, then polish and dimple as needed. The wing box seems to take a little more time, mostly the main spar for me. Your second wing will go much faster, like mine.

We are expecting some sub zero temps starting tomorrow afternoon through the weekend and into next week, a real buzz kill for working in the garage!