Ken's Sonex 1243

[Sonex1243]

Working stainless steel for the first time. Started assembling the upper forward firewall filler neck. The .016" 1/2 hard stainless bent easy with the seaming pliers and the HF bending brake. Pilot drilling was slow and tedious. Cleaned up the rest of the plans page detail parts.

[Sonex1243]

Finally finished the upper firewall after many flying and weather distractions. SNX-F17 plans page complete.





Started digging out the SNX-F16 spar tunnel and miscellaneous parts.

[Sonex1243]

Small snag with the F16 spar tunnel, didn't have 120 degree countersinks, only 100 degree. Quick order, always need more tools, and deferred. Finished F15 and F14 pages, one more to go before the forward sides take shape.









The machine angle and match hole are great, just been cleaning up tool marks more than anything.

[Bryan Cotton]

Looks good Ken! Maybe you can catch up with us since we are off rebuilding the car.

[Sonex1243]

I don't think I could catch up with you Bryan, you would have to take a looong time off!

[mike.smith]

Do yourself a HUGE favor when you install the fuel tank and make a catch pan with drain around the filler neck!! Just start at this link and browse forward from there.

http://www.mykitlog.com/users/display_l ... 960&row=26

[Waiex 49]

I agree completely with Mike.
Installing a catch pan and drain tube for the fuel filler is a good thing.
Otherwise any spilled fuel ends up in the cockpit!
I'm glad I did one of these on my Waiex.

[Sonex1243]

Excellent idea guys. Did you install after the tank was in then? Thinking about making up a blank now.

[Waiex 49]

I did mine with the fuel tank installed.
I made a practice "template" catch pan from cereal box cardboard.
Then I made the final catch pan out of aluminum sheet using the measurements of the template.
Not sure if you could do a catch pan without the tank installed as you kind of need to see where the tank filler neck fits into the filler box.
I fitted a 90 degree "street elbow" fitting (from Autozone) through the side of the filler box.
From the elbow fitting I ran a hose down the firewall to allow a drain for any spilt fuel.

Best of luck with your project!

[Sonex1243]

Finished SNX-F15, 14 and 13 plans sheets for the forward fuse sides. Laid all the pieces out to get an idea where everything goes. Study sheets and take a deep breath and start drilling like a mad man!



It has also dawned on me that I will be back to polishing once both sides are done before riveting..