Sonex 584 Builder Log
June - September 2004
Last update: September, 2004
June 1
Right elevator skin. Aligned inner end rib. Did this with great
care, as the control horn will attach to it and the assembly must be
precise. Pilot holes drilled and then reamed to full size. 1 hour.
July 5
Right elevator skin, ailerons. Measured, marked, drilled, clecoed new
end flap rib. Measured, marked, drilled, clecoed new elevator skin rib.
Measured, drilled, clecoed aileron tip ribs. Trimmed aileron skins to
fit tip ribs. After all the problems with these, it was great to be
done with them... and they fit great! Filed, deburred, sanded all of
the above work. 7.5 hours.
July 17
Final sanding and deburring of ribs and skin. Clecoed and riveted. Flap
complete! 7.0 hours.
August 28
Aileron. After beburring all hinge line holes, was attempting to file
out nip from snips around counterbalance notch when skin cracked.
Decided to scrap skin and replace. Will attempt to reuse ribs and
counterbalance assembly. 8.0 hours.
August 31
Completed deburring and sanding out drill scratches in elevator skins.
Riveted skins together sans end ribs (in order to assemble skins to
control horn.
|
Elevator skin clecoed and ready to
be riveted! The masking tape on the end row of clecoes is a reminder
NOT to rivet those... I don't want to rivet that rib in until the
control horn is fitted. |
|
Ready,
aim, rivet!
The Sonex kit comes with approximately 10,000 rivets. Technically, a
pneumatic riveter is not required, but you had better have one hell of
a good set of arm muscles if you're going to use a hand riveter on the
entire airplane!
|
September 7
Horizontal stbilizer clip. Began fabricating two clips (SNX-T06-06)
from channel stock. One completed. 2.0 hours.
|
One
down one to go. Not the most exciting of parts but a step forward for
me in that these were made from raw stock and involved the first use of
my bending brake.
|
September 8
Right aileron: Cut old right aileron skin to use as pattern for
new. Made marks on both in same locations, used to match positions on
new (could not simply place atop new as skin thickness would cause
errors in match drilling holes to existing ribs). Also fabricated two
forward root clips for horizontal stab. 5.5 hours.
September 11
Right aileron and horizontal stabilizer clips. Match drilled holes in
new aileron skin. Filed, sanded, and finished all for tail clips. 2.4
hours.
September 12
Trim tab: Rounded off corner of attach point, drilled attachment hole.
Bent end 90 degrees as per plans. Rounded off other corners and filed.
Measured, cut, and drilled hinge stock for trim tab. 2.0 hours.
Septermber 14
Right aileron: Continued work on new right aileron. Cut notches
for counterbalance assembly, drive plate, filed and sanded. Test fit
ribs. Used old aileron back piece (carefully positioned and clamped) as
pattern for match drilling rib holes on back side. Once done test
fitted and clecoed everything. Began work on reverse match drilling
aileron hinge holes on ribs. 3.5 hours.
September 22
Right aileron and trim tab: Completed deburring and sanding
right aileron with exception of tip rib end of skin.
Fabricated trim tab cable holder clip. Cut and drilled piano hinge for
trim tab and elevator. 3.0 hours.
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