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Sonex 815 Build Logs
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Date: 3-14-2006
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Number of Hours: 5.00
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Manual Reference: F22 + other
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Brief Description: Shear web, phenolic, bottom skin
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Spent about 1.5 hours fabricating the .032 angles for the aft seat belt mount assemblies. This included drilling the angles to the sheet stock, plus drilling the .125 attach fittings to the assembly, final sizing the holes, disassemble, debur, reassemble and rivet. Spent about 1.5 hours working on the phenolic blocks for the forward and aft rudder cable fairleads. Drilled all of the holes with the block at as-shipped size, then cut it into the 4 fairlead mount blocks. This way it was easier to clamp into the drill press, and did not have a tendency to slip. I recalled from building #0042 that the phenolic block would slip out of the clamp and be drawn into the 1/4" drill bit, making the rivet attach holes useless. Keep the block big, and use a hold-down clamp in the drill press vise. Spent about 1 hour installing the phenolic blocks onto the 2 aft verticals. Found that the phenolic blocks interfered with installing the side skin rivets, so I had to grind a divot into the blocks to clear the rivet. Found this on the first one after it was riveted to the vertical, so the grinding was kind of tricky. On the 2nd, ground it while it was still loose in hand. Spent about 1/2 hour drilling the bottom skin (plans-only activity) to the hole pattern that I had already marked the hole locations. Spent about 1/2 hour remaking F22-05 - found some 2x2x.125 to remake the part from.
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Seat belt attach points, aft shear web.
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Drilling 3/4" holes. Held vacuum hose up while drilling so no mess.
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The deep hold-down clamp is needed for these holes to avoid going all the way through.
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