I have started to make some of the details before completing the tail cone
section - (October 6, 2004). I followed the
plans building sequence (for the most part, as I did not attach the bulkhead
brackets on the Spine until the formers were in place). I attaching the skin to former #5 and
# 1, then fitted #2,#3,#4 . Caution: I would NOT attach the lower
bracket (F20-09) on former # 1 until the skin has been attached. this will
prevent buckling of the skin to former # 1. I had to re-make F-20-01 L/R again.
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used formers to trace material out
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filing both sides to be the same
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using fly wheel cutter to cut out lightning holes
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using formers to bend and form parts
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forming/bending F-20-01 forward former on my Workmate. One of the many additional tasks if you build from scratch.
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Caution: Do not attach this part until turtle deck skin has been attached
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tracing 2nd turtle deck skin
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filing both turtle deck skins
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laying out wholes (equal spacing)
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I had to re-make sholder harness attachment, added 1/4" wider on both to clear the former
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turtle deck skins being attached. Attached Spline to one side and drilled pilot hole, then attached the other side
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painted underside with NAPA primer
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Former #5 being attached. attached this one first per plans. The bolts are used to allign rib. I tried using Tape like others but it did not work
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starting to drilling out pilot holes t o1/8"
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starting to fit and drill bulkhead formers (11/2/2004)
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I am leaving the bottom off untill I am finished. Will need access for ridder cables, wire, etc.
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My Halo effect... Let the Angels protect all who fly in my Sonex.
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After alodning - Bulkhead formers riveted to sides
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Next, putting the skin on and rivet brackets to bulkheads, then skin to bulkheads and sides
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right side finished
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left side finsihed
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Getting to these nuts in the Box assy drove me NUTS. Hard to get to...
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