• Prosper, TX
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At 11:00am on January 20, 2011, Chris Aysen said…

Shannan -  Sonex is a nice aircraft. I'm considering one when I build my low wing. But enjoying my 701 right now. Good Luck with your build!


At 7:00am on September 25, 2010, Jake Reyna said…
I was thinking about my suggestion and making 12' laminated beams would be best. You could add a 4' piece of plywood to give you the 12' table for the wings. Use screws to attach the plywood to the beams. Make 4 - 4' x 3 1/2" laminated beams to use to build the wings, this gives you clearance for the clecos.

This is easy to do if you have a table saw.
At 6:49am on September 25, 2010, Jake Reyna said…
Shannan, I used a 3/4" 4x8 sheet of plywood for my table and added some 2x4's for stiffeners. For the base I used Stanley folding sawhorses I purchased at Home Depot, here is an Amazon link. Fold the sawhorse to adjust the height. You don't want the table to high when working on the wings. The wings are 12' long, but can hang off the ends.

To build the fuselage, I ripped some 3/4" plywood into 3 1/2" strips and made laminated beams, 4 strips 3" thick, and used 4 jackstands to support the fuselage bottom. Using individual jackstands allows you to level the fuselage. I used a laser on a tripod for accuracy.

This is much easier than building tables, etc., and makes it easy to break down to give you space to build. A 4x12 table takes lots of space.

If I was going to do it over again I would build the tailfeathers, flaps and ailerons and then the fuselage and FWF, engine, install the panel etc. This takes the most time. By the time you get this all done you will be an expert and can build both wings in 4 weeks if properly motivated, then you're done and ready to attach.

At 10:51pm on September 24, 2010, Ron Lendon said…
12' x 4' work tabel
Here are the plans I used.

Only modification was to plane the beams because I had access to the equipment.
At 4:28pm on September 24, 2010, Shannan said…
I have been done with the rudder for a while. I have been so busy with work, and life (In that order) I haven’t continued on with my project. The bug has bitten and I have got to get going again. The rudder went together very well and looks good. The most difficult thing for me getting the centerline of the ribs when drilling through the skin. I am going to order one of those fancy tools for just this reason, however in the spirit of ingenuity I fastened two hacksaw blades together, filed the teeth off and used the stock holes to line up drill points. Slip the skin between the points and KAPOW! Worked for me anyways. I will post a picture of it and my finished rudder as soon as I have time I promise. If I can every figure out how to take all my digital pics and get a slideshow to play fast enough it makes a stop motion-ish short film. Pretty cool.
At 8:48am on May 26, 2010, Shannan said…
I backdrilled the rear rudder skin, and cleco'd on the the skeleton. I then slipped the nose skin on, and adjusted the spar to 90 degrees, then directions say to use hole finding tool to line up the center of the nose rib to be drilled for the nose skin and I only have one question. What is a hole finder tool? I watche the Homebuilt Help DVD and will probably jut go with their method of checking the angle and extending the centerline from the main spar. Anyways, I had to go inside to have dinner with the wifey so I will finish up the ruddder another day. It looks like a rudder now though, its not far from complete. Need to see about ordering the rest of the empanage. Do they discount the rudder from that or do you have to order the whole kit? I will figure that out too so I know how many penny to roll.
At 11:07am on May 17, 2010, Shannan said…
Primed the whole skeleton, but will probably only do contact points on skins. I need to learn to drill out rivets, as I am not happy with one of mine. For the record MEK smells horrible, but it does remove the stickers, markings, and grease really easily. I'm on to the skins when I get a free moment. I'm a bit nervous for some reason handling them, Im guessing since this will be the cover of the book so to speak. Oh yeah, I got some retractable Sharpies......Forgot to retract....One more Sharpie bites the dust. Note to self: invest in Sharpie.
At 11:26am on May 12, 2010, Shannan said…
Debured rest of rudder parts, & marked center lines, as well as marked ribs locations and orientation. Unfortunatly I discovered I was shipped wrong clecos from supplier, so I will have to wait on some 5/32 black ones for the rudder horn/bottom rib. I could go ahead and move on to other ribs, but I am still in the scared first time builder phase.I must follow plan ver-batum. Need to order a primer. Still have not decided on type, or coverage.(just contact points, or whole parts?) I guess I will do some reading on that while I wait for my clecos. Also i left the cap off my first Sharpie marker. Something tells me that will not be the last one that bites the dust

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