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Sonex 815 Build Logs
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Date: 1-20-2007
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Number of Hours: 2.00
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Manual Reference: W07
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Brief Description: LH Wing assembly
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Got the wing turned over and drilled the upper portion of the leading edge skin. Last part to drill was the wing root doubler, which on the left wing is 3 ribs wide to provide the entry step. Marked the lower outboard corner on this step doubler and drilled a hole there, and drew lines 1/4" from the edge along the bottom and outboard sides. Unclecoed the inboard upper skin to slip the doubler inside (but didn't want to drill through because the ribs shift). Lined up that lower outboard corner of the doubler and put a cleco in it, then shifted the doubler until the lines were lining up in the skin holes. They didn't line up exactly, but I got both lines to be visible beneath all the holes (it appeared as if the lower outboard corner of the doubler was slightly under 90 degrees, but it was something really close like 89.7 degrees to get the lines I drew to be visible in all the skin holes). So I unclecoed the entire upper aft skin, put it on the floor on a board with the doubler underneath, and drilled through all holes to transfer the pattern. Then put the upper aft skin back on the wing, put the doubler back on the outside, and found that the forward (long skinny) part of the doubler that wraps around the wing was wrapping itself away from where it should be - the whole thing was trying to angle into the fuselage. So I leaned on it, wrapped it, removed the root ribs, and drilled through from inside to outside, using a series of C clamps along the doubler to hold it in the right place. Problem with this effort is now there is a bulge where the wide part of the doubler (the step-on portion) joins up with the skinny part. I have seen this done as 2 pieces of metal on other airplanes. Probably same kind of issue - it's very difficult to keep a skinny strip 7' long wrapped around the whole wing and lined up, especially starting at one end (upper aft) rather than at the middle (leading edge) and wrapping each 3.5' section back. Haven't decided yet, but I'll probably cut it and piece it. One advantage to th
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Wing root doubler.
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Bulging area.
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Doubler wrapped all the way around.
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