Builder's Log
DateAssemblyInstructionPartDescriptionLinks
11/03/2013 Fuselage F02 F03-02 F03-04 F03-07 F03-08

F03-08 Shear Angle.
Used the hack saw to cut the Z02-03 Angle stock to the rough length. Used the band saw to cut the sides of the angle to the rough widths.
F03-07 Spacers.
Used the band saw to cut the .032 sheet to the rough size.
F03-04 Spacers.
Used the band saw to cut the 3/16th by 1.5 inch bar stock to the rough length.
F03-02 Channel.
Used the hack saw to cut the Z04-03 Channel Stock to the rough length.

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11/04/2013 Fuselage F02 F03-02 F03-03 F03-04 F03-07 F03-08

F03-08 Shear Angle.
Used files and scotch brite wheel to get to final shape and size. Drilled the #40 pilot holes per the plans.
F03-07 Spacers.
Used the scotch brite wheel to get to the final shape and size.
F03-04 Spacers.
Used files and the scotch brite wheel to get to the final shape and size.
F03-03 Fittings.
The kit provided the part cut to the proper shape and with pilot holes drilled. I up drilled the three 1/8th and one 1/4th inch holes. I used files and the hand scotch brite wheel to clean cut marks from all the edges.
F03-02 Channel.
I used the band saw to cut to proper length and finished to proper length with files and scotch brite wheel. I drilled and up drilled the two 1/4th inch holes. For the 1-3/4th inch hole I drilled using a step drill up to 7/8th inch hole. I then used the nibler to get close to the final size. I finished to the final size using files and the hand scotch brite wheel. For the notches at the lower corners I drilled the corners to get an approximate radius. I then used the band saw to cut the notches into the holes drilled in the corners. I finished to final shape and size using files and the scotch brite wheel.

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11/06/2013 Fuselage F02 F03-01

F03-01 Rear Spar Carry Through Assembly.
I first lined up the F03-03 Fitting with the F03-05 Angle Fitting using a AN4 bolt in the 1/4th inch holes. I clamped the two parts together. I used the drill press to drill three #30 holes in the angle fitting using the 1/8th holes in the fitting as a guide. I clecoed the holes as I went so I was able to remove the clamp to get the third hole.
Next I lined up the fitting and angle fitting with the F03-02 channel again using a AN4 bolt in the 1/4th inch hole. I made sure the bottom edges were parallel and clamped them in place. I then drilled the 1/8th and 3/32nd holes through the channel using the other parts as a guide.
Next I remove the angle fitting and aligned it with the F03-04 Spacer. I clamped it in place. I used the drill press to drill the 1/8th inch holes in the spacer using the holes in the angle fitting as guide. I clecoed as I went and removed the clamp to drill the final 3rd hole.
I clecoed the angle fitting and spacer back on the -02 assembly. Next I up drilled the 3/32nd holes to #30 size for future rivets. Then I up drilled the three 1/8th inch holes to 3/16ths for the AN3 bolts.
Next I took the assembly apart and deburred all the holes.
Then I assembled the assembly using clecos for the rivets and AN3-7A bolts in the three holes.
I then repeated the process for the other end of the assembly.

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12/30/2013 Fuselage F02 F02

F02 Wing Rigging.
I started preparing for the putting the wings into the fuselage. I removed the gear legs and gear mounts. I removed the side gussets and vertical angles. I also removed the aft spar tunnel assembly. I then removed the lower skin of the aft fuselage.

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01/01/2014 Fuselage F02 F02

F02 Wing Rigging.
Today I started the wing rigging.
With the help of a good friend I inserted the wings into the fuselage. I had to file a little at the top of the fuselage opening on the left side. With a little raising and lowering of the wing tips I was able to insert the three 1/4" pins in the three alignment holes in the spars. The fuselage is level from side to side.

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01/03/2014 Fuselage F02 F02

F02 Wing Rigging.
Continued work on the wing rigging.
First I worked on centering the wing in the fuselage. I measured from the attachment block holes to the side fuselage skins. I was able to get it to within 1/32nd difference. Next I setup the tubing with windsheild washer fluid to check for wing level. I also verified that the fuselage was still level. I tried to insert a shim under the spar to raise the right wing but there was not enough room. I will need to pull out the wing some so I can fill the top of the opening that the wing spars go into the fuselage. This should allow the spar to go up so I can insert a shim to level the wings. I also tried to set the incidence in hope that it might allow enough room above the spar. It did not allow enough room.

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01/04/2014 Fuselage F02 F02

F02 Wing Rigging.
More work on the wing rigging. <>br>I removed the leveling tubing.
With some help I pulled the right wing out of the fuselage. Also partially pulled the left wing out of the fuselage. I filled the top of the fuselage opening for the right wing spar. I also up drilled the 3/16th holes on the rear wing spars to 1/4 holes. This matches the holes on the rear spar carry through. Pushed the left wing and then the right wing back into the fuselage.
I then centered the wings in the fuselage.
I set up the wing leveling tubes. I inserted a shim between the lower longeron and right wing spar. This leveled the wings.
Using clecos I put the aft spar tunnel, aft side vertical wing attach angles and gussets back into their place in the fuselage.
I connected the wing rear spars to the rear spar carry through using pins.
That is it for today.

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01/05/2013 Fuselage F02 F02

F02 Wing Rigging.
I continued with the wing rigging.
I verified that the wings were still level.
I set the wing incidence by placing a 2x4 and wood shims under the wings next to the fuselage. I measured to be sure that the distance from the bottom wing skin to the bottom of the fuselage skin was 3 5/32 inches. I clamped the wings in that position.
I checked to be sure that the wings were square by measuring from the tail to the out board corner of the top wing skin per the plans.
I started installing the rear spar carry through.
I drill some of the pilot holes from the side attach angles to the fuselage and the rear spar carry through.

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01/06/2014 Fuselage F02 F02

F02 Wing Rigging.
Rear Spar Carry Through.
Clamped the shear angle in place. I used the "Tight Fit" drill attachment and a 90 degree attachment to drill the pilot holes.
I removed the rear spar carry through assembly.
I finished drilling the pilot holes for the side attach angle. I then up drilled those holes to the #30 size for the rivets.
I put the assembly back in the fuselage and up drilled the holes through the shear angle and the fuselage cross piece.
I again removed the assembly.
I the attached the shear angle to the spar carry through. I drilled and up drilled those holes to the final size of #30.
I clecoed the side attach angles to the rear spar carry through. I then up drilled the holes to the #30 size. I used the drill press to carefully back drill the 1/4 inch hole through the side attach angles.
I then clecoed the rear spar assembly and side attach angles back in the fuselage to check that the pins alignment. The pins alignment was good.

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01/07/2014 Fuselage F02 F02

F02 Wing Rigging.
Rear Spar Carry Through.
I finished installing the Rear Spar Carry Through. I removed the rear spar carry through and angles from the fuselage. I attached the shear angle to the rear spar carry through with rivets. I put the assembly back into the fuselage with clecos. I installed all the rivets I could get to with the wings on. I could not do all the rivets for the side angles. I inserted the bolts to hold the rear spar in place.

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01/08/2014 Fuselage F02 F02


F02 Wing Rigging.
Drilling the Main Spar Attach Holes.
I was so busy I did not take any pictures of this process. I will take a few after the fact pictures tomorrow.
I had help from a friend.
I followed the step by step instructions in the plans. I did not use the 3/8 in bit with the 1/4 in pilot. I up drilled from the back to the front in 32nd in increments from 1/4 to 3/8.

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01/09/2014 Fuselage F02 F02

F02 Wing Rigging.
Rear Spar Carry Through.
With the wings off I was able to install the remaining rivets for the side attach angles.
Drilling the Main Spar Attach Holes.
After close inspection of the holes today I determined that the hole through the right hand forward wing attach angle on the side of the fuselage was not good. The hole was not a close fit to the bolt. All other hole locations appear to be good. So I have decided to replace the RH Fwd attach angle. Today I carefully drilled out all of the rivets and removed the RH Fwd Attach angle. I ordered a replacement from Sonex. I will install it when it arrives.

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01/11/2014 Fuselage F02 F02

F02 Wing Rigging.
In addition to replacing the RH Fwd Attach Angle I have decided to replace the Attach Block that is next to that angle. That is the Attach Block on the Left Wing Main Spar on the right hand side. Today I fabricated that attach block from 1" x 1 1/4" bar stock. I drilled the two 1/4" holes and installed it on the end of the Left Hand Wing Spar. I used a "D" drill bit to get tight fit holes. I will drill the 3/8" hole after I install the new RH Fwd Attach Angle.
Vents.
Today I also started assembling the side vents that I purchased from Van's Aircraft. These are the vents used on the RV-12 and back vents for the RV-10. I have seen a few others use these vents on their Sonex. So I have decided that I will give them a try.

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01/20/2014 Fuselage F02 F02

F02 Wing Rigging.
I received from Sonex the replacement Right Hand Forward Wing Vertical Attach Angle. I match drilled holes in the attach angle using the existing holes in the fuselage assembly. I counter sunk the holes where it attaches to the spar tunnel. I deburred all the holes. I then installed the rivets called out in the plan.

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01/21/2014 Fuselage F02 F02

F02 Wing Rigging.
I cut a 4 inch piece of steel bushing stock to be used to drill the pilot hole for the new attach block and attach angle. I put it in the drill press and filed and sanded the out side until it would fit into the 3/8th inch hole. I drilled the inside until a 1/4 inch drill bit will go through it.

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01/23/2014 Fuselage F02 F02

F02 Wing Rigging.
With the help of a friend I was able to redo the right hand hole for the main spar. First we mated the wings together out side of the fuselage. We left the left wing in the wing stand. We put the right wing in position on top of the left wing spar. I aligned the holes. I put the bolt in the left hole. I put the 1/4 inch pins in the three alignment holes. I put the 3/8 inch OD bushing in the right hole as far as the hole existed from the previous drilling. I clamped the spars together. On this step all that will be drilled is the new attach block. I drilled through the bushing with 1/4 inch drill approximately 1/2 inch into the new attach block. I took out the bushing. I then used the 3/8 inch drill bit that I had dulled all but about 3/4 inch at the tip. I drilled into the new attach block approximately 1/2 inch with the 3/8th drill bit. I then repeated the bushing and 1/4 inch bit for another 1/2 inch. Then the 3/8th for that 1/2 inch and then the rest of the way with the 3/8th inch bit. We the put the wings back in the fuselage. I used the three alignment pins to position the wings and spars. I clecoed the aft spar tunnel and aft vertical angles in place. I inserted the 3/8th inch bolt in the left hand hole. I used the bushing to be sure the right side was aligned. I then used the 3/8th inch bit to drill through the forward RH vertical attach angle. I drilled from the back to the front using the existing holes to guide the drill bit. The holes turned out great. I also noticed that the rivets by the hole in the front vertical would interfere with the nut for the bolt. So I drilled out those rivets and put them back in from the inside.

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