Darick's Sonex #1646

[Darick]

My last airplane always had an oily bottom so I decided to try the oil separator. Trying to keep up with Bryan's polishing quality is difficult so I polished the separator mounts to stay in practice. :roll:

[Darick]

I bought the vernier type mixture control thinking it would fit on the Sonex throttle but it was too big. The mixture control just fit into the small triangular space on panel corner. Then the throttle control had to be mounted lower which turned out nicely because then, the cable fits nicely on top of the trim control mount adjacent to the flap handle. I'm still working on a parking brake arrangement.
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[SonexN76ET]

Darick,

Your set up for your controls is identical to mine. I have had no problem with this placement and everything is very intuitive when you are flying.

I also have the Vernier control for the mixture. I believe this allows the engine to be run at peak smoothness and efficiency. I had the button lock control earlier, but the Vernier allows much more precise mixture control.

For the terminating end of the wire on the mixture control check out this :

https://www.aircraftspruce.com/catalog/appages/wiregrip.php

"WIRE GRIP - Is a unique fitting which securely attaches to solid wire end push-pull cables. Uses a "pin vice" gripping action to attach a cable. The 5/8" long 10-32 threaded end will attach a clevis, ball joint, or other hardware for use with mixture controls, carb heat box, cabin air, or other applications, resulting in a clean, professional installation."

for use with this AN665 THREADED CLEVIS TIE ROD TERMINAL assembly:

https://www.aircraftspruce.com/catalog/appages/an665terminals.php?recfer=10989

I believe this AN grade solution is preferable to the wirestop that many people use.

Great looking work on your plane!

Jake

[Darick]

Here is the final installed location of the outside air temp probe, in front of the Naca vent. I didn't polish it because the paint design will cover this area.

[Darick]

After installing the throttle and mixture cable, there is quite a bit of unsupported cable circling around the engine to the carb. So I adel clamped them together then added two aluminum supports about 12" from the firewall then again at the forward most end of the curve before going into the carb.
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The unfinished blue fuel line can be seen on the firewall. I'm designing the fuel delivery system based on Jeff Shultz's design.

Here's the most forward clamp for the throttle mixture cables.

This forward support is version one, made up of three pieces of aluminum. I'd like to make it simpler.

[Darick]

The Sonex control stick grip has a nice soft feel. I soldered the PTT wires to the switch.
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I cut off about 2-1/2" from the stick and it clears the subpanel by about 1".

[Darick]

[Darick]

Finally finished the fuel delivery system. From the tank, there is the usual shut off then a flexible line to a 90 degree bulkhead fitting. I used three washers as a doubler at this fitting, one on the inside and two on the forward side. Two were needed on the forward side to get sufficient space from the firewall so the components would line up.



After the 90 degree fitting is a TEE fitting from which a drain valve will be added when I get the cowl fitted. After that is a Jegs 40 micron fuel fitting, followed by the "Red Cube" fuel flow sensor.



A braided SS hose with fire sleeve goes from the Red Cube to another TEE, then the Aeroinjector. This TEE is for the burb tube which will have a Curtis drain valve at the top of the cowl. Again I have to wait until the cowl is on to finish this so I can make the valve flush with the top of the cowl. This drain valve has a flat push button which will be ideal for making it flush with the cowl and easy to operate for the burb tube operation. Aircraft Spruce 05-01865, SAF-AIR CAV-110.


Thanks again to Jeff Shultz for the basic design and part numbers.

[Darick]

Drain line...I guess this is almost a gascolator.
First picture is the bracket and McMaster bulkhead fitting...


Second pic...bracket with Curtiss drain valve, McMaster bulkhead fitting 5454k87 and aluminum tubing installed...


Third pic...completed drain line..



Fourth pic...burp tube with "push button" type drain valve at top. The idea is to have access to the button under the fuel fill door on the cowl. If this doesn't work for some reason, I'll put a small hole in the cowl right over the button.

[Darick]

Windshield bow finished. I didn't have enough bench space to bend the bow so I used the floor and plywood circles fastened to a 4 x 4. It was a bit of an overkill but you use what's available.

All the holes are drilled at this point but not yet tapped.


Everyone has their own way of getting the nuts on those screws way up front holding the windshield. This is mine...just taped the wrench to a metal yardstick...worked great...a small piece of tape on the underside kept the nut in place.


Windshield installation complete. Removing the protective plastic makes a much better picture.