Builder's Log
DateAssemblyInstructionPartDescriptionLinks
1/9/2012 Wing W08 W11-03 W11-04 W11-03 Wing Attach Blocks - Cut from 1 x 1.25 6061 T6 Bar Stock using the band saw to cut to length and cut 3/16th chamfer. Used belt sander to smooth cuts to proper size. W11-04 Shim Plates - Cut from .063 6061 T6 sheet using the hack saw. Used scotch brite wheel to smooth and trim the cut edges. Photos
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1/10/2012 Wing W08 W11-03 W11-03 Wing Attach Blocks - Using the drill press I started drilling and updrilling the 2 3/16th holes. Photos
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1/11/2012 Wing W08 W11-03 W11-03 Wing Attach Blocks - Using the drill press I finnished drilling and updrilling the 2 3/16th holes. Photos
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1/12/2012 Wing W08 W11-03 W11-05 W11-02 W11-03 Wing Attach Blocks - Pollished all sides to remove any cut or machine marks. Aligned W11-03 with W11-05 End Attach Angle and drilled the remaining 3/16th holes. W11-02 End Wing Attach Assembly - For one of the assemblies I used the drill press and drilled and updrilled the 1/4th holes for the two AN4-15A bolts. Photos
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1/13/2012 Wing W08 W11-02 W11-02 End wing Attach Assembly - On further inspection of the assembly from yesterday I decided that the 1/4th holes for the AN4-15A bolts were not tight enough for the tight fit holes called for in the plans. The bolts are .246 and the holes appear to be the .25. I called and discussed this with Kerry at Sonex Tech Support. He said that what I did was OK but it would probably be better if I did them over. I ordered new material and smaller drill bit from Aircraft Spruce. Photos
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1/18/2012 Wing W08 W10-06 W10-06 Tip Attach Angle - Cut two from Z01-03 Angle Stock. Photos
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1/20/2012 Wing W08 W11-05 W11-05 End Attach Angle - Continued shaping the cut out. Did not turn out right. Cut out another using the band saw and belt sander. This one matched the shape and dimensions per the plan. Photos
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1/23/2012 Wing W08 W11-02 W11-03 W11-05 "W11-03 Wing Attach Block - I used the drill press to drill and up drill the 3/16th holes per the plans on the new attach block. W11-02 End Wing Attach Assembly - I used the drill press to drill and up drill the holes for the assembly. I drilled the one 3/16th hole and the two tight fit holes for the AN7-15A bolts. I used a ""D"" bit for the finnal hole size for the two bolts. On one of the assemblies I then reemed out the hole just enough for the tight fit. Tomorrow I will do the other assembly." Photos
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1/24/2012 Wing W08 W11-02 W11-02 End Wing Attach Assembly - Reemed out the holes on the other assembly. On both assemblies I installed the bolts and torqued them to 65 inch pounds. Photos
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1/24/2012 Wing W08 W11-06 W11-06 Root Wing Attach Assembly - Finnished drill ing the holes on the two W11-03 Wing Attach Blocks. Using the Wing Attach blocks I located the holes on the W11-07 Root Attach Angle. Then using the drill press I started the holes. Photos
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1/25/2012 Wing W08 W11-06 W08-01R W11-06 Root Wing Attach Assembly - Finnished drilling the the tight fit holes. I installed the AN4-15A bolts and torqued the bolts. W08-01R Right Main Spar Assembly - Drilled the holes and installed the MS24694-S56 and -S58 screws to attache the W11-02 End Wing Attach Assembly. Photos
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1/26/2012 Wing W08 W08-01R W08-01R Right Hand Main Spar Assembly - I located the W11-06 Root Wing Attach Assembly using the location hole on the spar web. I drilled the holes and installed the 3 AN3-7A bolts and the 3 MS24694-S58 Screws per the plans and predrilled holes in the spar. Started locating the W20-02 Root Rib Attach Angle on the spar assembly. Decided to wait until tomorrow th start drilling holes. Photos
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1/27/2012 Wing W08 W08-01R W08-01R Right Hand Main Spar Assembly - I installed the 8 AN3-7A bolts at the inboard end of the bottom spar cap. I riveted W10-06 Tip Attach Angle to the end of the spar on W10-07 Tip Web which was already on the pre assembled spar. For rib stations 1011 and 12 drilled holes in the spacers for the spar web. Clecoed the ribs in place to see what it will look like. Photos
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1/28/2012 Wing W08 W08-01R W08-01R Right Hand Main Spar Assembly - I attached the W20-02 and W20-03 Root Rib Attach Angles to the spar assembly. I first located W20-02 and clamped in place. I then drilled the 1/8 pilot holes through the spar. Next I clecoed both W20-02 and W20-03 in place and updrilled to the 3/16th size holes. I installed the AN3-10A bolts washers and nuts per the plans. Photos
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1/29/2012 Wing W08 W08-01R W08-01R Right Hand Main Spar Assembly - I attached W11-10R RH Tie Down Fitting and W11-11 Outboard Vertical Stiffiner Angle to the spar assembly. I located these parts by the predrillied holes in the upper and lower spar caps. I clamped the parts in place and drilled 5/32 holes to match the predrilled holes. I then clecoed these parts to the assembly. I then used the predrilled holes in the angle to locate the four holes in the spar web. I drilled those four holes with the #40 #30 and #21 drill bits. I also up drilled the hole in the upper spar cap using the #21 bit. I then updrilled the trhee holes in the lower spar cap using a 3/16th bit. The parts where removed and deburred. The parts where reattached using clecos. The two AN3-6A and one AN3-7A bolts where installed per the plans. I then used the Sonex bolt and hammer method to install the 5 rivets per the plans. Photos
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1/30/2012 Wing W08 W08-01L W08-01L Left Hand Main Spar Assembly - I attached the W11-02 End Wing Attach Assembly. I installed the 8 AN3-7A bolts at the inboard end of the lower spar cap. I attached the W11-06 Root Wing Attach Assembly. I attached W20-02 and W20-03 Root Rib Attach Angles. Photos
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1/31/2012 Wing W08 W08-01L W08-01L Left Hand Main Spar Assembly - I attached W11-10L LH Tie Down Fitting and W11-11 Outboard Vertical Stiffiner Angle to the spar assembly. I located these parts by the predrillied holes in the upper and lower spar caps. I clamped the parts in place and drilled 5/32 holes to match the predrilled holes. I then clecoed these parts to the assembly. I then used the predrilled holes in the angle to locate the four holes in the spar web. I drilled those four holes with the #40 #30 and #21 drill bits. I also up drilled the hole in the upper spar cap using the #21 bit. I then updrilled the three holes in the lower spar cap using a 3/16th bit. The parts where removed and deburred. The parts where reattached using clecos. The two AN3-6A and one AN3-7A bolts where installed per the plans. I then used the Sonex bolt and hammer method to install the 5 rivets per the plans. Photos
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1/31/2012 Wing W08 W08-01R W08-01L Main Spar Assemblies Mating - I made three 3/32 pins to align the spars. I set the spars on 4 saw horses and used the pins to test the alignment. I found that a washer on one bolt on the left spar was not clear of the mating surfaces. I will move that washer to the other side. Photos
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2/1/2012 Wing W08 W08-01L Main Spar Assemblies Mating - I reinstalled the bolt with the washer on the other side. Photos
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2/1/2012 Wing W08 W08-01R W08-01L "Main Spar Assemblies Mating - I set the spars on 4 saw horses and used the three 3/32 pins to align the spars. I made two 3/16th pins and inserted them in the two wing attach block holes. I then clamped the spars together inplace. After verifying that there were no clearence problems and that the spars where aligned I updrilled the 5 holes to 1/4th inch. The three 3/32 holes were done 1/8 5/32 3/16 7/32 and 1/4th. I started with the center hole. After reaching 1/4th I inserted a AN4-10 bolt to help hold the location. The two attach block holes I first redrilled with 3/16th. The next larger 6"" drill bit I have is 1/4th so I went directly to the final size. I did use candle wax to lubricate the drill bit." Photos
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