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Sonex 815 Build Logs
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Date:  6-30-2007
Number of Hours:  5.00
Manual Reference:  L03
Brief Description:  Tailwheel install / main gear completion

Took about an hour to finish off drilling the holes in the caster and bolting up the tailwheel. Ended up making shims for either side of the wheel itself because the "fork" tightened down on the "tire" and prevented it turning. Ended up with .030 shim on one side, .025 on the other (why not .032? I have some .015 Al and started by making two .015 "washers" but these weren't enough). Other misc activities over the rest of the time: Drilled through the main gear axles (through the gear legs) to put the hole in the 2nd side of the axles. That way it lines up just perfect with the hole through the Ti. Fit the windshield bow (but did not drill the holes to the fuselage yet). Tried clamping the Aeroconversions throttle handle to the aft spar box angle - note if you plan to use this throttle, keep that aft LH spar box angle full width - do not taper it down towards the upper end per print - you will need material here for the throttle attachment. I might be able to get it where I want it - high enough to clear the trim handle, but I might end up adding a doubler to that spar angle for support. Shortened the axle spacers by 5/32 to put the brake drums completely over the brake shoes. Cut the vent line for the fuel tank (had formed this yesterday while waiting for Ti drilling to cool off). Drilled and fit the brake cable guides to the axles. Note: drill the guides before bending the washer to fit the axle. If the washer is bent, there isn't any good way to clamp it for drilling. "Adjusted" the cable guides with a screwdriver (pried them to a better angle) at the cable exit end. Cut the "ST option" flap handle mount from the flap drive rod. That thing was digging into my leg with the flaps retracted, and isn't needed. Also greased the phenolic blocks mounting the flap drive rod. Rolled the fuselage outside for a photo, put it back in nose-first, and set the h-stab on it to check for how much room it takes - too much for another car to be in there, so the h-stab will go on towards the end.
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Windshield bow in place, fuel vent in place.

Windshield bow in place, fuel vent in place.

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Tailwheel mounted.

Tailwheel mounted.

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Rolled it out for an overall photo.

Rolled it out for an overall photo.

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