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CHUCK'S WEB SITE
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Date: 4-6-2022
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Number of Hours: 2.50
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Manual Reference: SNB-L01
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Brief Description: Discovered Mistake And Testing Modification.
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I communicated with Kerry at Sonex about the main gear mounting, and he informed me the inner tube inside the weldment was not a stop, but that the leg ends had to go inside this tube, and the hole at 3 1/2" down from the top of the weldment tube was the correct hole position in the weldment tube. The legs had to go into the inner tube at the top until the leg hole and the weldment tube hole both lined up and then it needed bolted at the 3 1/2" mark per the plans.
I have discovered one place where Sonex does not build completely according to the plans (I have a quick build). There was a change in the manufacturing process and the plans have never been updated to reflect this change (screw and rivet holes inside the spar tunnel that are now only countersunk, rather than being dimpled and countersunk per the current plans). This was a very minor change that was not documented and was not a problem according to Sonex, as they know this manufacturing change inside the spar tunnel is structurally sound. However, I made a very big mistake here, because I assumed this problem inserting the main gear legs into the weldment to the proper depth was a similar situation. It seemed very minor that I needed to place the mounting hole in the weldment tube at 4 1/2" down instead of 3 1/2" down. I should NEVER assume like this. It was a mistake. I should have gone to Tech Support for confirmation, or as they later provided me, a clearer explanation.
However, I still couldn't get the legs to go inside the inner tube/sleeve to provide the full insetion into the weldment. As a possible work-around, I did wooden mock-ups of the legs where I turned down the diameter of the end of the legs just enough that they would firmly insert into the inner tube/sleeve, and could be mounted at the proper 3 1/2" distance. I then submitted this to Kerry at Sonex Tech Support for consideration/comment.
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Created wooden leg mock-up to determine how much diameter had to be reduced to insert into inner tube.
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Wooden mock-up leg inserted into the weldment inner tube/sleeve to proper depth for 3 1/2" mount hole.
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