Fuselage
Fuselage Completion #18 (Elevator trim knob and pitot/static routing)
Total Build Time: 988 Hours This post includes the installation of of my elevator trim knob and my plans for routing of my pitot/static and LRI (lift reserve indicator) tube connections. My elevator trim knob will be located on the lower left side of my instrument panel. I located it to be as far from … Continue reading
Fuselage Completion #17 (Electrical Wiring #1)
Total Build Time: 964 Hours. I started my wiring by making connections forward of the firewall, and then passing initial wires through the firewall. I labeled all wires more than a few inches in length using printed labels and clear heat shrink. I used a pick tool to shove the labels into … Continue reading
Fuselage Completion #16 (Instrument Panel)
Total Build Time: 944 Hours. I began cutting holes in the instrument panel to install all of my avionics, switches and air vents. I started with the air eyeball vents since I wanted to set them as far outside on the panel as they would fit to give me the most room in the middle … Continue reading
Fuselage Completion #15 (Firewall Mounting)
Total Build Time: 931 Hours. I removed the engine after having marked up the firewall and planned for component installation. I installed nutplates where practical in order to ease removal/replacement in the future. I made a couple spacer plates for the gascolator installation in order to allow clearance for the sump drain past the … Continue reading
Fuselage Completion #14 (Swing Back Canopy Completion)
Total build time: 920 hours. I ordered the swing-back canopy kit offered by the American Sonex association. The kit inclues pre-rough-cut parts (all need some finishing work), including one welded part that I would not be comfortable making myself, hardware (nuts, bolts, rivets), and written plans that include pictures. Here is a link to the kit. … Continue reading
Fuselage Completion #13 (Firewall preparation and battery box)
Total Build Time: 910 Hours. Once I had the engine, exhaust and intake mocked into place I could plan the firewall layout. First step was to identify the usable area on the firewall. I then (with help from Bill) made some cardboard cutouts to assist with planning the layout. The cutout below represents my … Continue reading
Electrical System and Instrument Planning
Total Build Time: 873 Hours. To plan my electrical system, I studied other builder projects, the sonex plans and the book Aeroelectric Connection. Some general concepts I followed were to use fuse blocks (rather than circuit breakers) for wire protection, 2 main fuse-block-busses (main and avionics), in-line fuses to protect all wires not otherwise connected … Continue reading
Fuselage Completion #12 (Canopy frame, trimming)
Total build time: 866 Hours. With my Mom and Bill in town for the week, I wanted to use their extra sets of hands to help me with moving and fitting the plexiglass canopy. I began by preparing the canopy frame. I’m actually installing a swing-back style canopy which I will detail more in another … Continue reading
Aerovee #8 (Mounting the engine, oil cooler, exhaust manifold)
Total Build Time: 846 Hours. So I had an engine resting on a table next to the airframe, and I took these pictures while trying to decide how many people I should invite over to help me mount the engine to the airframe. Upon looking at those photos, a thought dawned on me, and I … Continue reading
Fuselage Completion #11 (Windshield fitting)
Total Build time: 820 Hours With the fuel tank and glare-shield temporarily in place, I turned my attention to the Polycarbonite (Lexan) windshield. The typical (plans) method is to fit the bow first, then cut the windshield to fit the bow. Since I am tall, I decided to follow a method advised by some other Sonex builders, … Continue reading
Fuselage Completion #10 (Fuel tank fitting)
Total Build Time: 806 hours. With my Aerovee engine build on hold due to cylinder head issues, I turned my attention back to the airframe. I moved forward with the initial fitting of the fuel tank. The very durable rotationally molded polyethelyne fuel tank sits beneith the glareshield (and in front of the pilot). It is held … Continue reading
Fuselage Completion #9 (brake system)
Total Build Time: 745 hours. For the brake system I intended to use the system as called for in the plans, with an addition of a turnbuckle to allow for easy brake cable tension adjustments. Sourcing the parts for the brake system ended up being more of a chore than I’d imagined. There were several … Continue reading
730 Hour Project Update (Timelapse Video)
It’s now been 11 months since I took delivery of my Waiex kit last November. I took off 3 months of building during the summer, so I essentially have spent 8 months of actual building time on the project. I previously made an update at 500 hours and included a time-lapse video that showed the … Continue reading
Fuselage Completion #8 (Flight Control pre-rigging, VIDEO)
Total Build Time: 730 Hours. With my wings still attached, I decided to do as much as I could before removing them once again. Space in my basement is limited, so eventually I will need to remove the wings both to continue working, and to get the plane out of the basement at the end … Continue reading
Fuselage Completion #7 (Wing Rigging)
Total Build Time: 722 Hours. Finally, the big day has come. My wings have been sitting on a rack in the corner of my basement for the last 7 months. Now I will finally be able to pull them off the rack put them onto the plane for the first time. To prepare the fuselage … Continue reading