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Zenith CruZer & Sonex Logs
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Date: 9-1-2008
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Number of Hours: 2.70
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Manual Reference: SNX-W15
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Brief Description: Rib Gusset
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Took 3 days off to head for the boonies of Kansas. Nice getaway.
Labor day had every intention of putting in 10 hours or so on the Sonex, but I had to labor on other things on Labor Day. Spent a good productive 2.7 hours completing the 32 rib gussets for the forward and aft ribs.
Deburred the laser-cut prepunched gussets, then bent two flanges on each; one for stiffness, one for mounting coincident with the rib flange. Used a 13" Harbor Freight bending brake, and finished off the 1/2" mounting flange with flanging pliers to get it to 90 degrees.
Only hitch was with the forward rib gussets, SNX-W15-06 and -07. The plans had two different-outlined gussets, but in 2006 Sonex went to the laser-cut parts, which are identical. 8 of the 16 have flanges bent up, the other 8 have them bent down. This is what differentiates between the -06 and -07 parts.
However, the -06 gusset interfered with the upper flange of the rib. The only way I could make it fit was to trim the edge off, which was no big deal. Only issue is that this trim puts one rivet hole closer to the edge than I'd like. I have the question in to Kerry @ Sonex, so we'll see what happens tomorrow.
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SNX-W15-06 Gusset Interference
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SNX-W15-06 & -07 Gussets
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SNX-W16-06 & -07 Gussets
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