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Sonex 1093 Construction Log
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Date: 2-22-2008
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Number of Hours: 0.00
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Manual Reference:
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Brief Description: TIPS: Initial Discoveries
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Buy a good respiratory filter and use it!. I've decided to use a prefessional model (Image 1). Two days of sanding, grinding and Scotch Briting and I started to feel like I had TB. Using a cheapo $5 filter works, but don't think they'll last long. Chest cold feeling disappeared in a day and the mask really shows the stuff that I'm not now breathing.
My power tool bench is about 10" too high, especially after I put wheels on it. Will cut it down later.
Need a soft brass brush for cleaning files that load up on the aluminum.
For bending the 3/16" main spar strap to the 1/2" radius, I used a 7/8" spark plug socket for the inside and two 1" oak dowels for the outside, then squeezed in the vise.
When making small clips, cut a little extra long, do the bend and then trim each end to size. Helps if you aren't sure where the bend will actually end up.
The Scotch Brite wheel requires a real gentle touch. Any pressure leaves indentations and gouges whenever I've tried to use it except for ends of pieces that can be held perpendicular to the wheel.
The belt sander works OK for smoothing straight edges shorter than the sander. If longer, the round end of the sander digs in to the piece. I'm now using an orbital sander with 150 grit paper to start and hand finishing with a Scotch Brite maroon pad.
On thin channel stock, I use the Andy snip to cut 1/4" to 1/8" out, a round file to radius inside corners (gently or it's too rough), and flat files to finish (Scotch Brite pad for final smoothing).
The vixen file can be used to smoothly file even the .025 skins like the elevators and it doesn't create aluminum dust like the sander and SB wheels. But it takes some practice to make smooth edges.
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