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Sonex Project

A record of the Sonex project being undertaken by EAA 506.  When updating this section of the site, please add your build records to the relevant subsection - i.e. fuselage, wings, etc.  Should an additional section be needed, please add it to 'Miscellaneous' and contact the site administrator with a request for the additional section. Once it has been created, the record will be moved to the new section. 

Subcategories from this category: Fuselage, Wings, Tail, Elevator, Miscellaneous

Posted by on in Sonex Project
we finally have the turtle deck in place and it went together like it was designed to do. we had Glen, Ron ,Bob ,Mike and myself and could use a some additional help...

Posted by on in Sonex Project
We finished drilling the top wing skin and started on the bottom skin but ran out of clecos so we decided to start on the fuselage
Recent comment in this post - Show all comments
  • Joseph Mancusi
    Joseph Mancusi says #
    Some rapid and good progress! WOW.
Hits: 154 1 Comment

Posted by on in Wings
Well we finally made it past the root rib. The root rib did not fit correctly so we had Bob Scott touch it and like magic it fit so we were able to fit and drill the top aft skin....
Tagged in: Sonex

Posted by on in Wings
The group showed up for some pre-Christmas work on the right wing.  All of the work was finalizing the fit of the rib closest to the fuselage and the adjoining root rib, which is offset.  Because of the wing attachment points which require thicker pieces of aluminum on the spars, these ribs require trimming and adjusting.  Ironically, these ribs have taken more time to complete than the entire rest of the wing.  Bolted brackets on the main spar also reduce the amount of space to work on the attachment doublers when drilling the holes for the rivets. Additionally, a setback was the attachment bracket was reversed by accident, requiring all of the rivets on the nose root rib to have to be carefully drilled out and the error fixed. One positive, Heidi sent Wayne along with apple tart, which provided fuel for the crew! ...
Tagged in: Ribs root ribs Wing

Posted by on in Wings
Most of the work done this evening was on the two root ribs.  Because of the offset of the spar due to the right wing spar and the left wing spar being bolted to each other, the two root ribs need to be adjusted (trimmed) in their length to fit the bracket on the spar on the trailing edge of the wing.  A great deal of measuring and consulting of the plans took place before cuts were made and the new end bracket on the one spar was fabricated.  On the the root spar, positioning it for drilling also required quite a lot of fiddling to get everything to line up properly. ...
Tagged in: root ribs Sonex Wing

Posted by on in Wings
A group of six turned up to work on the wing for the Friday 7 2012 session.  Work accomplished included: Centering lines were marked on the ribs Some rivets not flat were drilled out and replaced Predrilled holes were drilled to the correct size in the ribs and rear and main spar Everything was taken apart, deburred and reassembled Some thought was put into fitting the skins, but some additional tools will be needed   One item demands further investigation.  It isn't clear from the plans if the following should be on the inside or outside of the spar.  The bracket in question is in the image below. ...
Tagged in: Deburring Ribs Wing

Posted by on in Wings
The right wing ribs are clecoed  in place.  Work was done by Jordan Normark and Mike Maltby.
Hits: 177 0 Comments

Posted by on in Wings
b2ap3_thumbnail_Sonex-23-Nov-2012-img2.png
The .250 holes for joining the wings were reamed  and the table was assembled. Work performed by Wayne Milbauer, Ron and Jordan Normark, Terry Karlson.  ...
Tagged in: Reaming Sonex

Posted by on in Miscellaneous
Long-time member Jerry Stein donated the Sonex to EAA 506 (The chapter is a 501(c) (3) charitable organization) and in August, the aircraft was moved from his home to the Chapter Clubhouse via Wayne Milbauer's home.The members who turned out to help move the aircraft that rainy Sunday morning included Wayne Milbauer, Ron Normark, David Johnson and his buddy from Ashville, Steve Johnson, Norman Smit, Terry Karlson, and Joe Mancusi.  The Chapter cannot fly or operate an aircraft but we can build a kit.  ...
Tagged in: donation Sonex