Sonex 584 Builder Log
April - May 2004
Last update: September, 2004
April 3
Left aileron. Deburred ribs and skin. Cut skin edges and notches.
Filed and sanded smooth. Reamed out holes in counterbalance assembly to
full size and deburred components. Measured, marked, drilled, deburred
left aileron piano hinge. 3.0
hours.
|
Measuring the locations for the
rivet holes on the hinge for the aileron. Too much fun. |
April
11
New right flap. Aligned and drilled pilot holes for ribs. Measured
elevator trim tab and marked on aluminum stock. 2.5 hours.
|
Okay...
so when is the stupid auto timer going to take the picture...?
Maybe I didn't set the damn thing right.... I think I'll just get up
and walk over there...
*FLASH!*
Stupid new digital
camera...
|
April
13
Right flap. Aligned and drilled pilot holes for end rib. Reamed out
all previous pilot holes to full size. Deburred ribs; began deburring
flap skin. 2.0 hours.
April 18
Right flap, right aileron. Completed deburringright flap skin. Measured
and marked new aileron counterbalance plates. Fabricated new channel
assembly (used snips to cut channel stock instead of band saw this
time... much better). Cut lead and sanded for counterbalance. Drilled
pilot and final holes for counterbalance plates and attatched ribs. 3.0
hours.
April 20
Right aileron counterbalance-- drilled pilot holes in lead
counterweight. Clecoed assembly and reamed out holes in counterbalance
plates and lead. Perfect fit this time! 2.0 hours.
|
The benefit of experience... and
some help from a professional metal worker (thanks Bruce!). |
April 23
New right flap. Cut skin to shape. Measured and marked hinge rivet
holes. Drilled pilot and final holes for hinge. 2.0 hours.
April 25
Aligned ribs/counterbalance assembly in aileron skin. Drilled pilot
holes and reamed to full size. Alignment was almost perfect-- finally
getting good at this. Used Dremmel snake drill attachement for holes
close to rib/counterbalance plate assembly. Kind of a pain.
Tail: Measured and marked both elevator skins. Cut to shape. Measured
locations for ribs and pilot holes on right elevator skin. 4.0 hours
total.
April 26
Right flap, right elevator skin. Deburred hinge line holes on right
flap skin. Verified locations of pilot holes and drilled. Marked
elevator ribs. 3.0 hours.
April 29
Left aileron. Drilled out remaining piano hinge holes. This was made
more complicated by the fact that the counterbalance assembly was now
riveted together and could not be partly disassembled to allow easy
drill access. Also deburred piano hinge and aileron skin. 3.0 hours.
May 4
Right elevator skin. Aligned ribs with pilot holes; drilled and reamed
holes to full size. Aligned piano hinge and drilled pilot holes. 4.0
hours.
May 29
Left aileron. Drilled out remaining piano hinge holes. This was made
more complicated by the fact that the counterbalance assembly was now
riveted together and could not be partly disassembled to allow easy
drill access. Also deburred piano hinge and aileron skin. 3.0 hours.
May 31
Left elevator. Measued and marked locations for elevator ribs. Measured
and marked locations for rivet pilot holes on all sides and drilled.
Measured, marked, cut, and drilled piano hinge, then clamped it to the
elevator skin and drilled pilot and final holes. Aligned end rib,
drilled pilot holes and reamed to full size. 4.0 hours.
|
Left elevator skin with hinge
clecoed in place. I tested the hinge pin and other hinge half to check
for fitting-- all was well. |
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