Ken's Sonex 1243

[dbdevkc]

Having suffered through this with my gear legs, I would offer a simple solution

https://www.aircraftspruce.com/catalog/ ... ckkey=9233

This jig allows you to set up well-centered holes on round pieces, provides a drill guide, and allows you to clamp the piece.

I loaned mine out and it wandered away, if I can get it back I will put it up for the tool loan program.

My two cents.

As I was at a place in my build where I was to drill a 1/4" hole through the F23-01 tail wheel mount, so I sucked it up and purchased the Drill Rite tool. It works great. In the case of the tail wheel mount, I wanted the hole to be in line with the brackets that are welded on. The tool clamps on tight, and I drilled the 1/4" hole with no issues at all - perfectly centered and straight through both tube walls.

[Sonex1243]

Got mine coming as well Kevin!

[dbdevkc]

It is pricey. I will loan mine out to local (Northeast - NY, NJ, CT, Eastern PA) builders - close enough that if I don't get it back I can go knock on their door when I need it again. ;)

Kevin

[Sonex1243]

Played with the drill guide today and it worked great on the Ti rod for the tail wheel, just had to add a shim since it was loose in the "V" due to the small rod size. I had to pull the mount from the fuse and drill it as well since I forgot to do it before installing it. The irony here is that I managed to get the tail wheel pivot fitting a little off center when fitting and will have to order a new piece.. My drilling woes continue!

In hind sight, I shouldn't have piloted the pivot fitting ALL the way through both sides, it would have been better to transfer the pilot hole to the rod, drill the rod, insert and finish drilling through the pivot back side.

Drill guide clamped in the vise. Cordless drill worked great.


Transferring pilot hole in caster to Ti rod for drilling


Not how it is supposed to look!


Mistake while trying to transfer the hole through the backside of the pivot fitting...

[Bryan Cotton]

Been there, done that, got the T shirt. I welded a collar on mine and redid it.

[sonex892.]

I used this drill guide method to transfer the hole from the existing hole in the titanium rod to a new tailwheel.

[Rick524]

A couple of things to do to the Sonex tailwheel before flight--Change the two small screws as per the service bulletin.
Replace the bolt going thru the wheel to a longer one so some threads are showing.

Rick

[Darick]

Been there, done that, got the T shirt. I welded a collar on mine and redid it.

Yep, me too.

[Sonex1243]

Lol, looks like I am not alone then. I may have to run to wally world and get another pack of T-shirts since I am running low and my scrap bin is growing.

Rick, those were going to be done soon, just waiting for the hardware to arrive.

Has anyone done the other Sonex SB-006 replacing the AN4C landing gear bolts with AN4 steel bolts? They are cad plated and the plans were adamant about cad coming in contact with Ti, will probably just need to remove the cad plating?

Sonex892, thanks for the drill guide info.

[wlarson861]

Has anyone done the other Sonex SB-006 replacing the AN4C landing gear bolts with AN4 steel bolts? They are cad plated and the plans were adamant about cad coming in contact with Ti, will probably just need to remove the cad plating?

I changed to the AN bolts in 2011 right after the service bul. came out, did not remove the cadmium. Plane flew 417 hrs before the mount was removed for a new engine and the bolts were still good. Titanium gear legs were in great shape with no signs of wear or pitting. Same gear legs were re-used with the new mount.