I've wanted to fly a self-built aircraft ever since 1967, when I first obtained my FAA Airframe & Powerplant Mechanic certificate. Since I tend to be a risk averter, especially when it comes to flying homemade aircraft, I considered many designs before selecting the Sonex. The Sonex is a very strong, all-metal design, offering exceptional performance per dollar. My reason for building it is very simple. I like to build stuff in my garage.
The Sonex can be built in a variety of configurations including three engine choices, center or dual control stick, and tricycle or conventional (tail wheel) landing gear. Mine will have center stick, conventional gear, and a 120 horsepower Jabiru engine, manufactured in Australia. The center stick will allow me to comfortably fly solo while seated in the center of the aircraft. For carrying an occasional passenger, the two occupants will be able to sit side by side, with the control stick between them.
Sonex Specifications
Sonex Plans are extremely complete. The plane can be scratch built using only raw materials and plans. To speed up the construction process, a kit featuring many prefabricated parts, is available. I will be using a combination of scratch built and prefabricated components.
Shop tools used to build the Sonex are surprisingly simple. My wife and I attended a builder's seminar at the Sonex factory in Oshkosh, Wisconsin. I was surprised to learn they recommended cutting aluminum angle components with a wood cutting band saw. I was really skeptical but I tried it anyway. I used a 1/2" wide blade w/8 teeth per inch and waxed the blade before each cut. It worked great!
One of my absolute favorite shop tools is my grandfather's 1939 Homecraft drill press. I can't explain it but I just feel good every time I use it.
Here are some machined angles I cut with the band saw and drilled with the drill press. My plan is to make as many small parts as possible, prior to assembling anything, in order to conserve shop space. With most of the small stuff completed, assembly should go rather quickly. At least 200 Sonex aircraft are already flying. I'm not breaking any new ground here. Many builders have published excellent web sites. I plan to focus on building an excellent airplane, rather than making a great web site.
Several of the aluminum angle pieces needed to have their angles opened or closed prior to machining. These steps, milled into vise jaws, worked well for closing the angles.
I purchased several 4' x 12' sheets of 6061 T6 aluminum for the wing ribs and bulkheads. The supplier rolled the sheets and shipped UPS. The shipping charges were very reasonable.
I cut the 26 forward wing rib blanks with hand shears and used a flycutter in my drill press to make the lightening holes.
Outer flanges of the ribs are bent over the form blocks with a rubber mallet.
Flanging dies were used to add stiffness to rib webs around lightening holes.
Modified Vise Grip pliers were used to flute the rib flanges.
Here are some completed forward ribs. Check back from time to time. I'll be adding more photos as the project progresses.
