Builder's Log
DateAssemblyInstructionPartDescriptionLinks
11/20/2010 Tail T08 Drilled holes on rudder drive horn using the drill press. Also deburred holes and edges. Photos
12/1/2010 Tail T08 "Cut a notch in a 2x4 and wrapped a 1"" pipe with duct tape to assist in bending the of the rudder drive horn. Used the arbor press to bend the drive horn." Photos
12/2/2010 Tail T08 Finished drilling and up drilling the holes in all the parts for the rudder drive horn. Clecoed the parts together. Photos
12/3/2010 Tail T08 Rivetted the rudder drive horn. I also cut the rudder skin to size and shape to fit the drive horn. Photos
12/4/2010 Tail T08 Laided out the location for the pilot holes on the rudder skin. Photos
12/5/2010 Tail T08 Started drilling holes and clecoing the rudder skin and ribs. Photos
12/7/2010 Tail T08 Worked on drilling holes to attach the drive horn to the skin. Photos
12/8/2010 Tail T08 Made template and drilled holes for rudder hinge. Photos
12/9/2010 Tail T08 T08-02 Drilling and UpDrilling Holes Photos
12/10/2010 Tail T08 T08-02 T13-02 Debur and remove scratches and Planning Hinge drilling Photos
12/13/2010 Tail T08 T08-02 Drilled holes for hinge updrilled all holes started debur and clean Photos
12/14/2010 Tail T08 T08-02 Finished debur and cleaning. Clecoed and started riveting. Photos
12/15/2010 Tail T08 T08-02 Finished riveting the rudder. Photos
12/18/2010 Tail T08 T12-01 T12-02 T12-03 Drilled pilot holes on T12-0102. Layout and started cutout on T12-03. Photos
12/19/2010 Tail T08 T12-03 T12-07 T12-03 - Cut wood form bent 90 flange drilled pilot holes and debured. T12-07 - bent 35 using arbor press. Photos
12/20/2010 Tail T08 T12-08 T12-08 - Cut basic shape and bent 57 degree flange at end. Photos
12/21/2010 Shop T08 Modified Manual Rivet puller for angles in tight places Photos
12/22/2010 Tail T08 T12-08 T12-04 T12-06 "T12-08 - Drilled all pilot holes and deburred. T12-04 - Cut out shape cut 5 degree angles on side drilled 1"" hole using step bit on drill press and deburred all. T12-06 - Cut rough size from .063 flat stock" Photos
12/27/2010 Tail T08 T12-06 T12-09 Cut rought size from .063 stock. Bent angles. Filled to final size. Used drill press to drill pilot holes. Photos
12/28/2010 Tail T08 T12-10 T12-06 T12-09 T12-10 - Layed out Cut out Drilled pilot holes and deburred all. T12-06 and -09 - Deburred and polished all sides & holes. T12-01 - Deburred Filed sides and polished out scratches. Photos
12/29/2010 Tail T08 T-12 T10-01 T10-02 T10-03 Finished deburring polishing etc all T-12 parts. Started ribs T10-01 T10-02 and T10-3. Cut to length. Finished T10-01. Cut and formed 57 degree flange on T10-02. Photos
12/30/2010 Tail T08 T10-02 Finished rib T10-02. Formed 90 degree flange. Deburred all edges. Photos
12/30/2010 Tail T08 T10-03 Started forming T10-03. Photos
1/3/2011 Tail T08 T10-03 Finished rib T10-03. Started studying drawing T09. Looked at how parts will be assembled. Photos
1/4/2011 Tail T08 T09-01 Started assembly of T09-01 Main spar assembly. Photos
1/5/2011 Tail T08 T09-01 Used drill press with #40 to drill pilot holes for all of T09-01 main spar assembly. Photos
1/6/2011 Tail T08 T09-01 Updrilled all #30 holes. Photos
1/8/2011 Tail T08 T09-02 Drilled #40 holes in T12-08 and T12-07. Also in T12-09 clip. Clamped many of the parts together to test approximate fit. Photos
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1/9/2011 Tail T08 T09-02 Drilled #40 holes in assembly with T12-10 clip. Photos
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1/9/2011 Tail T08 T09-02 Up Drilled #30 holes for assembly with T12-10 clip and T12-09 clip. Found clip T12-09 was not square to assembly. Decided to fabricate a new T12-09 clip. Photos
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1/9/2011 Tail T08 T12-09 Cut rought size from .063 stock. Bent angles. Filled to final size. Used drill press to drill pilot holes. Photos
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1/10/2011 Tail T08 T09-02 T12-09 T12-09 - deburred cleaned polished etc. T09-02 - drilled holes for clip T12-09 to attach to T09-02. Photos
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1/10/2011 Tail T08 T09-02 Cleaned polished etc all parts for T09-02. Clecoed together all parts. Riveted T09-02 per plans. Photos
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1/13/2011 Tail T08 T09-01 Drilled holes for AN3-7A bolts for attachment of T12-06 clip. Drilled pilot holes for attachment of T12-05 angle and spacer to 3/32. Photos
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1/14/2011 Tail T08 T09-01 Drilled holes for attachment of T12-05 angle and spacer to 3/16. Drilled remaining holes for AN3-6A Bolts to 3/16. Removed all clecos and deburred all holes and parts. Cleaned and polished etc. Reassembled with clecos ready for rivets. Photos
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1/15/2011 Tail T08 T09-01 Installed rivets per plan. Inserted bolts washers and nuts per plan. Appears that AN3-6A bolts are too long. Need to investigate and resolve. None of the bolts have been tightened other than the first AN3-6A bolt. Photos
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1/21/2011 Tail T08 T09-01 Check that material thickness are correct for T09-01 they are. Added a third washer to AN3-6A bolts per discussion with Kerry at Sonex. Torqued nuts for the 8 AN3-6A bolts to 23in-lbs. Installed the 2 AN3-7A bolts for clip T12-06 and torqued to 23in-lbs. Installed AN3-7A bolts for angle T12-05. Just hand tightend since the spacer will be removed. Photos
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1/21/2011 Tail T08 T08-01 Started putting T08-01 assembly (vertical stabilizer frame) together. Previously had drawn plan on table. Layed parts out on table per plan. Clamped parts together and to table. Drilled all #40 pilot holes and clecoed them together. Photos
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1/22/2011 Tail T08 T08-01 Located drilled #40 pilot holes and clecoed T14-04 (rib for tip) to top of assembly. Also located drilled #40 pilot holes and clecoed T10-05 (leading edge rib) to assembly. Photos
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1/23/2011 Tail T08 T08-01 Drilled all #30 holes for rivets for the assembly. Photos
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1/23/2011 Tail T08 T08-01 Removed all clecos. Deburred all holes. Reassembled with clecos. Riveted per plans. Photos
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1/24/2011 Tail T08 T08-01 Worked on positioning the Skin T11-01 and Hinge T10-06 to the assembly Photos
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1/24/2011 Tail T08 T08-01 Drilled #40 holes and clecoed Skin T11-01 (on the hinge side) and Hinge T10-06 to the assembly. Photos
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1/25/2011 Tail T08 T08-01 Worked on fitting tip to assembly Photos
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1/25/2011 Tail T08 T08-01 Sanded Tip and tested fit to assembly. Drilled #30 holes for skin and hinge on the hinge side of the assembly. Photos
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2/14/2011 Tail T08 T08-01 Deburred holes on skin and frame on hinge side. Made alignment marks on opposite side of aft spar. These marks are aligned with holes already drilled on hingr side of aft spar. Reassembled the skin to the frame and checked alignment marks with factory pilot holes in the skin. Ready to start riveting the one side. Photos
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2/15/2011 Tail T08 T08-01 Riveted port side except for top row (to allow insert of tip later). Drilled #40 holes and clecoed other side in place. Photos
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2/16/2011 Tail T08 T08-01 Drilled #30 holes. Deburred all holes. Reassembled prep for riveting. Photos
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2/17/2011 Tail T08 T08-01 Completed riveting all but top row of rivets. Slide tip in place and attached rudder to test fit. All appears good. Will wait to attach tip until decision is made about paint. Looks good. Feels good to have finished something that looks like it belongs on an airplane. Photos
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