Four days and no reply from Sonex Tech Support regarding my question. This is only the second time I've used Tech Support in over 630 hours of construction. Not particularily pleased. They were busy all week with events regarding the new Onex.
I did not wait for them any longer and thus minimally sanded the upper 2 inches of my gear legs and ultimately placed a small chamfer to the distal end. I was able to seat the legs after doing so. It was a neglible amount but I was concerned ; should I sand the gear leg or the retaining tube. Ultimately went with the leg; a decision that was supported by Tech Support when late on the fourth day I received an email response. Gee, thanks.
Placed the axles to the gear legs and used the Sonex "spacer" to set the 0.7 degree toe in. Marked the legs and secured the axle to it-temporarily. I then transferred the entire leg axle assembly to the drill press for the procedure.
Returned the legs to the A/C and secured the axle to the leg.
Placed the axle brake assembly and drilled retaining bolt.
New issue. It is well known that for some (most) builders there is insufficient clearance between the firewall and the rear of the gear tube of the engine mount. There is no room for a washer/nut to be placed without contacting the firewall. Some people have simply placed the head of the bolt towards the F/W and placed the washer nut forward. This is technically not good practice but... My concern was that you had to take the entire engine mount off to do this and if you every needed to remove a gear leg you would have to remove the entire engine! No thanks. So, I did what others have done and I drilled through the F/W and used two extra washers as a spacer between gear leg tube and F/W. I was then able to bolt the structure with the head forward and in a way that is easy to access as required. It also has the secondary effect of reinforcing the F/W.
All titainium is secured with Stainless Steel hardware.
