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Michaels Sonex #145 log
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Date: 7-5-2012
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Number of Hours: 0.50
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Manual Reference: C05-01
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Brief Description: Control stick assembly
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Before I can install the aft lower cabin structure permanently, I need to check that the front edges of the control sticks don’t interfere with the top of the spar tunnel. To do this I’ll need to assemble the control stick assembly first.
This seems to be a problem a few other Australian builders have experienced recently and one of them who was following my build progress suggested I check this now rather than put it all together and find out much later when installing the controls that there is a problem, thanks Rodger!
As I was told it seems there are slight differences in the control stick welded parts Sonex supplies which causes this problem for some builders.
If there is a problem I might have to remake the angles that attach the aft lower cabin structure and control stick assembly to the control stick assembly to the spar tunnel, raising the 1/4" holes that the control stick attaches to slightly (these holes are also copied in the channels of the aft lower cabin structure that attach to these angles but I’m pretty sure I can just elongate those if necessary as it is not the channels but the thicker angles that bear the load of the control stick assembly).
So on to the assembly, first problem, the bushings that are supposed to fit tight in the control stick frame in which the sticks will rotate are supposed to fit “tight”, mine do not.
Some quick searching on the Sonex groups revealed this is a common problem as well and the suggested solution (by Kerry from Sonex) is to use some JN Weld to permanently cold weld them in place so that’s what I did tonight, I need to let the “glue” dry now.
Second problem, I don’t seem to have enough SF812-4 & SF812-3 bushings supplied with my controls hardware kit (I’ve only got 2 SF812-3’s and no SF812-4’s), I’ll need to order some of those and find something else to work on in the mean time, possibly the seat sling.
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