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Pauls Web Site
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Date: 8-28-2013
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Number of Hours: 6.00
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Manual Reference: W0?
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Brief Description: Starting Rear Spars and finishing Main Spars again
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After hearing from Sonex tech support, I decided to remake the one wing attach block that was improperly drilled. I clamped the new block to the old block, and drilled the holes that attach the block to the angle. This worked pretty well, though the holes somehow didn't line up perfectly with the angle. However, after another email to tech support, I've decided that it's nothing to worry about.
Next I re-mated the spars, and drilled the new attach block on the drill press. I sure wish I would have done this with the drill press last time - the hole drilled perfect.
I've since started on the rear spars. I expected that quite a bit of work, but surprisingly the spars are so simple they COULD be completed in one work session. I'm guessing 4 hours. This would include priming.
Unfortunately, the left spar channel that was laser cut and pilot drilled was drilled in the wrong place. You can see in the picture below. The good news is that Sonex is sending me a new piece at no charge.
While I waiting for the new piece, I decided to make the radius blocks that are required for the nuts to seat squarely with the bolt when tightened. This is necessary because the inside radius of the ange is so close to the bolt hole.
To make matters more complicated, the radius of the angle was 1/4", instead of the 1/8" listed in the plans. On top of that, I didn't have any 1/4" aluminum to make the radius blocks. Fortunately, a friend at work who is also building a plane came to the rescue, giving me the 1/4" aluminum I needed.
Though not shown here, I finally found a good use for my router. I had a 1/4" radius bit that made making the radius blocks much easier. As shown below, tonight I completed the for radius blocks needed for the rear spar
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Left Angle and Channel not flush
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Radius Blocks Complete
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