Ken's Sonex 1243

[sonex892.]

Ken. Take a look at this video of compounding on an airstream restoration.
https://www.youtube.com/watch?v=LVRzG5tp7B0

[Sonex1243]

Ken. Take a look at this video of compounding on an airstream restoration.
https://www.youtube.com/watch?v=LVRzG5tp7B0

sonex892, great video. I think I am finally having an "aha" moment. The first aileron skin came out real nice after 4 F9 passes. I have gone back and hit the flaps with another slower pass and got rid of the finger dabs. Waiting to compare the ailerons with the flaps and may go to another pass on all four pieces to get them the same if needed.

[Xenossoaring]

Finished the wing stand today. Built the one from the sonex forum, i think it was designed by another sonex builder. Came out real nice, got the right wing off the table and fit right into the stand perfectly.

[Sonex1243]

After overcoming a severe case of tunnel vision for a perfect polish, I am closing that chapter for good!

F9 shine is good enough. "C" will be done before riveting.


Ready for re-assembly.


Up-sizing to #27 for the over-sized cherry max rivets has begun.

[Bryan Cotton]

Looks good Ken. It is a couple weeks away, but I am trying to psych myself up for polishing that right wing. I have a funny feeling that Adam will have homework.

[Sonex1243]

Thanks Bryan.
Not much done other than getting everything up sized for the over sized rivets. Everything has been dis-assembled and awaiting deburring. Off to Sun and Fun tomorrow for the rest of the week!

[Sonex1243]

Deburring finally completed after a short hiatus. Assembled some surfaces to measure the length of the oversized rivets needed with a cherry gauge. Will be back to polishing with the "C" while waiting for the rivet order to arrive.



Nice little reamer for upsizing holes

[Sonex1243]

Finally after battling a nasty sinus infection and work, I finished all the skins with 2 passes of "C". Cleaned everything up and assembled the flaps for riveting.

Ran into a snafu with the cherry rivet gun, the spring from the universal pulling head disappeared. Luckily I found it and considered it a good stopping point. will shoot a few oversize test pieces to make sure the gun works properly.


Skins are finally comlpeted after a week of cold and sickness


Flaps assembled for the oversized cherrymax rivets

[Sonex1243]

Finally some headway! Finished riveting the flaps and started the ailerons.


Flaps riveted! Getting my confidence back after messing them up the first time.


Ailerons in work


Back side in work

These cherry max rivets are a little challenging to install, IMO, since the head diameter is smaller than the CCP's which makes it harder to ensure a flush fit on the skin before pulling the trigger. Definitely has me taking more time to ensure the bulbed head is seated right.

[Sonex1243]

Finished riveting the ailerons today, except for those pesky ones between the balance arms. Looks like my slim line riveter will need to be used with a wedge. I mounted / test fit the controls and the fit is good so far. The hinge pins weren't overly tight, except the left flap and all went in fine. No binding and everything moves without binding / squeaking.

Called it a good stopping point as tomorrow is a flying day to train a few crews for UAS chase plane duties. This NDSU agricultural aerial mapping side project will keep me busy through May and pick it back up late August / September.


Trying to mimic the trick photography



Odd seeing the work bench completely empty for once. Time to start the infamous "punch list" before starting the rear fuselage, but, something tells me though, to finish the wing tips and cut the scary holes in both wings for the LED lighting and install the lens's before moving to the fuselage.. Decisions, decisions..