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Sonex 815 Build Logs
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Date: 8-20-2006
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Number of Hours: 5.00
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Manual Reference: F16, F10
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Brief Description: Spar tunnel
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Spent about 3 1/2 hours to layout, cut, and drill hole pattern on the forward spar box z channel, plus drill the angle stock parts to the aft spar box L channel. Note from the photos, I put the angle stock parts on the wrong side to drill through initially (mistake), but the two lower angles were so close to the same in the hole pattern that they clecoed right up (pilot hole size) when reversed and moved to the correct (aft) side of the L channel. Got everything straightened out at pilot hole size, so the final size holes worked out right. The mistake started with the upper (large) angle stock part - I put that on the wrong side, and continued with everything else on the wrong side. I was confused when it came to adding the .090 side plates, and rounded the upper edge of these to fit inside the large angle stock part. Turns out they go on the other side and don't need to be rounded. No big deal. Took about an hour to do the countersinking: Cut down the m-stop cage to get the c-sinks near the radius of the angle (got the idea from Dick Hein). I figured if it makes the m-stop cage too unstable, they're only about $20, but it seemed to work out well. Last 1/2 hour or so was laying out and cutting F10-01.
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All dimpled.
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Making the countersinks.
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The cutoff from the microstop cage.
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