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Sonex 815 Build Logs
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Date: 8-18-2007
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Number of Hours: 4.00
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Manual Reference: D02
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Brief Description: Windshield installation
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Spent 1 hour trying to drill out / press out the broken off tap. Considered other fastening options - drilling a hole to either side of the broken off tap? This would leave an unfilled hole in the center top of the windshield. I had a section of 0.5" diameter rod from back when I thought I would bend my own bow, so now's the opportunity. Took 1 1/2 hours to bend the bow. I had traced the original bow onto the table top to set the size, then tweaked the new one until it pretty well matched. The idea now is to not tap any of these, but drill them to 11/64 and get longer fasteners. So I drilled the hole pattern into the new bow, up to 5/32, then realized the 11/64 drill bit I had burned up trying to drill out the tap. This was a VERY frustrating day. Shouldn't have even happened at all. But that's what you get for introducing a new process (tapping) which I don't know how to do. It is an elegant design - short screws into tapped holes, but for all this frustration, may as well just eat the weight of a little bit longer screws and be done with it. Besides, if I run screws with nuts, I don't have to worry about locking. Don't want to use loctite around the canopy because I don't know what chemicals it has problems with, and the print says definitely don't use loctite on the acrylic. I would recommend skipping tapping the windshield bow, but I don't know the structural implication of larger holes in the bow, so good luck with all that. I have to proceed this way else I might just take an axe to the whole thing.
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Pull towards to open. Push on left side to close the radius.
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New bow over the traced line.
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Broken off tap after all I could throw at it.
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