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Sonex 815 Build Logs
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Date:  5-11-2007
Number of Hours:  5.00
Manual Reference:  F09
Brief Description:  Fuselage floor structure

Completed the drilling of the parts installed in the fuselage in about 3 hours. This included drilling the side gusset plates. I did these by figuring out that the aft side of the gusset holes were 1/4" from the edge, where the left and right side gusset holes (to the fuselage side panels) were 3/8" from the edge. I drew these two lines on the part, and where they crossed, I drilled a pilot hole on the drill press. This let me cleco the gusset into the structure, where I held it by hand and started the forward hole to the side panel. I removed the part and drilled this hole through on the drill press. This gave 2 holes to hold the gusset with. I clecoed it back with these two through holes and just started the rest of the holes with the drill. I removed the part again and finished all the holes on the drill press. I clamped the doubler in place on the gusset and drilled it through on the drill press. Then all that remained was to cleco the gusset and doubler (F10-25) into place and final size the holes through the bottom skin. Time consuming, but easy. Took another hour to final size drill the rest of the holes not in the bottom skin with the structure on the work bench. Spent another hour deburring things and got most of that done.
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Drilled all this to final size outside of the fuselage.

Drilled all this to final size outside of the fuselage.

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What the lowered seat mod looks like.

What the lowered seat mod looks like.

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Another view.  Note idler is just off center so pushrod is on the centerline.

Another view. Note idler is just off center so pushrod is on the centerline.

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