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Sonex 815 Build Logs
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Date: 9-1-2007
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Number of Hours: 3.50
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Manual Reference: D01
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Brief Description: Canopy installation
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I knew this was going to take a while, but I didn't think there was that much in the frame itself. Today started by deburring the parts. Then riveted the cross brace to the aft frame, and riveted the side frames to the aft frame. Then inserted the forward weldments into the side frames, then the forward bow onto the weldments. Riveted all that. I used the hand rivet puller becaue the Harbor Freight one is dead. No longer releasing the stems without disassembly between each rivet, so not worth using. The canopy frame doesn't look like much, but it's 32 rivets on the weldments and 28 more on the cross brace. Then moved on to drill the hook angle drilled to the side frame. Put the frame on the fuselage, and the hook angle on that, and marked the hole locations. Drilled and countersunk the holes, then assembled the angle. It sat crooked on the square side tube. I recalled someone saying to use a round tube for the side because the inner radius of the angle stock is so large it interferes with the square tube. So I took the hook angle off, clamped it to the table, and cut that radius out using a dremel. So it fits together better, but still has a grabby motion. Put it back together and drilled thorugh for the shear pin. This itty bitty pin is the key to getting the latch closed - and it's held in place by a tapped thread in .049 material. I thought this was going to be a bad given my past experience with tapping aluminum, and I was right. Instead of breaking the tap off, all it did was enlarge the hole and not cut a thread. I'm thinking of a solution which does not rely on tapping anything.
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Lightening the spacer. Went from 68g to 60g. 13% reduction.
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Grinding the radius out of the angle.
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Full view of the angle being ground.
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