Bob's Plans built Sonex
S/N #243

Homebuilt Airplane     
Read Disclaimer  
 Last update:  Tuesday July 17, 2007
 Jab 3300 - Received Oct 6, 2006 Photos  Prop Arrives 10/21/06


 This page is Not owned or managed by Sonex Ltd. Sonex Ltd is not responsible for its content.


 
 Click to enlarge
       A real Sonex Airplane                                                   My current paint scheme
                   
    Why the Sonex ?

      Some of my criteria
1. All metal construction, low wing design, Tricycle Gear (my personal preference)
2. Affordable to build, own and operate (Sport plane)
3. Support from Local builders and factory. There are now (7) builders in the San Diego area.
4. Good performance (130 to 170 MPH) and reasonable payload (~400 lbs)
 

Photo's of my Building Progress and how I got started
 After spending several months reviewing material packs and plans I read the article in the February 2002 issue of Sport Aviation. That put the Sonex on the list of Planes to "Check-out". Purchased Info Pack and video, visited (2) local builders Chris Puntis #92 and Chuck Howard # 99 to check out their planes and ask questions. Then in May 2002, I bought some plans and got to work. I didn't even have a workbench until August.

My Photos & Building progress :
   click on links below to see photos of my building progress 
(click on each Photos to enlarge)
 Last Update: Tuesday July 17, 2007
                                            Start   ...........  Finished

  1. Vertical Stabilizer & Rudder    May 3 2002        July 26, 2002.. 129 Hrs
  2. Horizontal Stabilizer & Elev.   July 11,2002       Oct. 20 2002.. 128 hrs
  3. Wings, Flaps & Ailerons               
    3a. Pitot Assy.                        Oct. 19,2002      Oct. 22, 2002
    3b. Flaps                                Oct. 22,2002      Nov. 3, 2002 
    3c. Ailerons                            Nov. 3, 2002      Dec. 26, 2002
    3d. Wing Ribs                         Dec. 20,2002     Jan. 20, 2003
    3.e Wing Spars                       Jan.  14, 2003     Sept. 5, 2003
    3.f Wing Assembly                   Oct. 01,2003      July 14,2004
  4. Fuselage & Canopy                 
    4a. Rear Section                      July 14, 2004       October 2004
    4.b Turtle Deck                      October 6, 2004    Nov 16, 2004
    4.c Forward Section               Nov 16, 2004      
  5. Instrument Panel                         
  6. Engine  & cowling                          n/a
  7. Final Assembly & Pre Flight Testing

    Total Project Hours to date .............. 1,442 (10/12/2006) . If you purchase the Kit you can complete the project in 1/3 the time (IMHO). It's Time vs. $$$.

    MISC :   How I Alodine My Parts

    UPDATED :Todd's Canopy Photos  
    Oshkosh 2005
     
Assembly Pit-Falls To Avoid -  "Measure in metric and inches then cut......"
       1. Rudder - Rivet rudder side then bottom of horn
        2. Flaps a. Rivet Ribs to skin before riveting Drive Plate (see photos)
                   b. Flap Hinges are not the same length
        3. Attach bottom fuselage skin before horizontal brackets
      

Tools Required to build a Sonex

1. Power Tools
2. Hand & Air tools
3. Tool bench
4. Work bench (4'x12')

   WEB Sites to purchase Tools and Materials
Travers Tool (drill Bits, reamers, shop tools, etc) http://www.travers.com
Aircraft Tools Supply (Clecos, reamers, 3M, Dimple dies) http://www.aircraft-tool.com
Wicks Aircraft Supply http://www.wicksaircraft.com
Aircraft Spruce & Spec. http://www.aircraftspruce.com   
Instrument Panel Builder http://www.epanelbuilder.com
Todd's Canopies http://www.toddscanopies.com (Canopy Photos)
 
Changes and Options I may make to original design?
1. Toe Brake Photos - May change to some sort of cable system
2. Canopy Latch Mod
3. Instrument Panel (Stratomaster Ultra) Installed in Factory Plane
4. Glass Cockpit Instruments  NEW Dynon FlightDEK-180


Other Aircraft I looked at building:
 RV-9A - More expensive and involved than I was ready to commit to
 Zodiac - Didn't like the wing design and performance
 Lafayette - Nice design but pricey
 Pulsar - Decided to build metal plane
 Vision - Low number of kits & Decided to build metal plane
 
Links to other Builders & Sites
Sonex-Ltd. Factory Page

   
Sonex Ltd. Factory Planes

Link to of ALL the Sonex web sites

Locations of the Sonex Builders in US & CANADA (Google Frappr)

Photos July 17,2004 - BBQ Northern California Sonex Builders 
Send me an Email:
EAA Chapter 286 web (I am the President)-We meet at Palomar Airport (CRQ) the first Thursday of the month)
EAA Sport Pilot site

Photo I took at Camarillo fly in of Jack L and Eric (Red Devil) Sonex


Dave Koelzer Sonex Flight Simulator FREE

     

       

Here I am in a BD-5 at the San Diego Aerospace Museum and with my wife Laurie at the controls of a DC-3

Here we are in Sedona AZ. I Have my Commercial License and now in the process of getting my CFI License.  After 25+ years in the computer industry it's time to do something fun for a living. What do you think?

 

 

 

  My Wife's Website   

 

 
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