Building Sonex 982 Sierra X-ray

Bob Meyers' Unofficial Airplane Builders Log

I have been working some the last couple of days just not much to see. I'm in the process of cleaning up all the hinges, just to make sure no polish grit is inside of them. Not too hard. 
 
I also am working on storing the new pieces. Although most will go back to where they were, I want to make sure they are safe and out of the way. I also want to keep them fairly clean while in storage. 
 
In addition to the above I have been looking over lead times for the engine and avionics and planning their purchase. Some lead times - like for the prop - are long. I will be ordering some of these in the next several weeks. 
 
The wings will also have some wiring embedded in them so I have started work on designing the electrical system. It will have a 14v 20A electrical system. I have finally decided to use fuse blocks instead of circuit breakers with mostly fast-on crimped spade connectors. 
 
I don't have to decide much at this point to wire up the wings but I do have to finalize a few things and buy the wire and some connectors. I'll leave the finalized electrical system for much later. 
 
The project is moving along nicely. I'll also be doing some flying again this week. 

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Four days of dirty hard work and all the pieces have been shined up. 
 
Here are some pictures of before and after. 

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I started cleaning up the shop and after the table was cleared, I set out all the completed pieces. The picture at Christmas time showed the flaps and the vertical stabilizer. These images show the addition of the two ailerons and the horizontal stabilizer. 
 
It is hard to convey the scale in the photographs. Just remember that it is on a 4'x12' table. Standing in the shop, the tail looks very impressive. A lot is done!!! 
 
Enjoy the pictures. They are all on one page, just click on any that you want to see larger. 

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All control surfaces and both stabilizers are done! 
 
That feels like quite an accomplishment. I have decided that I will make the wings next. When finished, they will store flat against the ceiling very easily while I build the fuselage. 
 
I had pushed the wings back in my mind because they seemed too hard to attack too early, but with all that I have done I feel ready for them. I start by making the main spars. They will be the hardest part. 
 
Before I start on them I will probably polish up all the pieces I have made. I might start on that tomorrow. Then I will have to do some additional work to the table. The wings will use most of the table surface so I will have to move some of the things I have been keeping on the table. 
 
Now I just need some good weather to go flying. 
 
Here are the pictures of the finished left aileron. 

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The aileron is definitely a little trickier than the other control surfaces. I have just gone very slow but the result is great. 
 
Here are the pictures from the last couple of days. 
 
The second aileron is all marked up and ready for drilling tomorrow. 

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It's been a little cold in the garage but not really a problem with a sweatshirt. 
 
Here are the pictures from today. 

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It has been hard to get back in the rhythm I had going for the Horizontal Stabilizer. Cold, but not really too bad in the garage, Superbowl, and other distractions have kept work moving but slowly. 
 
Here are pictures of the work up through last night. I will get back to work this afternoon. 
 

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...just prep and cleanup. I hung the horizontal stab on a bracket I made for it out of alum angle with a couple of customized steel pins to hold it in place. 
 
The unit weighed in at 20 pounds. 
 
I cleaned up the work area and gathered all the parts for the ailerons. I may start them tomorrow (today really, looking at the time stamp) 

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Yes it is done. 
 
Made the elevator yesterday and finished attaching it today. 
 
Here are the pictures
 
The ailerons are next. When they are done, all the control surfaces will be done. 

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