This is the complete and uncensored story of my Sonex homebuild project

 The Year 2000 and earlier  2001 2002 2003 2004 2005 2006 2007

2008

Chinese Year of the Rat

2009 2010 2011
For about three years I researched the homebuild market, monitored the RV, Kitfox and other eMail lists. Then at the end of 1999 I finally decided for the Sonex. Then it took another half year until I finally received the plans and the rib forming tools via Ares Inc. Italy.

 January

Large cutouts, more engine stuff, panel layout

 January

Wing Attach Blocks, Fitting the Wingribs

 January

New Tools, Fwd Fuse Floor, Air Vent, Spar Tunnel, Pitot Tube Mount, Root Rib Attach Angles

 January

The Mainspar

 January

The Big Bend, Leading Edge Press Problems, Skinning the Wing

 no activities until July 2006

 January

Cable Fairing, New Idler, Levers and Pushrods, Elevator Pushrod, Control Stick Jam? Positioning the engine, Reinforcing the Seat Structure, Seat Cross-Tie Service Bulletin

 Januar

Kühlung Flugmotor, Luftleitbleche (Ducting)

 Januar Überlegungen zur Abgas-Anlage

 Januar

nix los inde Werkstatt

 Januar

 February

Instrument sub-panel, oil cooler ducting, still more engine stuff

 February

Pivot and other Blocks, Vertical Tail

 February

Fusealge, Aft End

 February

Test-Fitting the Spars, Still more from Mainspar

 February

Forward Wingskin Clecoed, Almost a Wing, Second Leading Edge Bend, New Aluminum arrived

 no activities until July 2006

 February

Flap Handle & Fuselage Floor, Trim Servo Cable Routing

 Februar

Vorbereitung Motorhaube (Cowling)

 Februar Konsol-Abdeckung, Flügelstützen

 Februar

Abgasanlage und komische Ideen

 Februar

 March

Tailcone, 'Pop'-Rivets, Wiring Diagram

 March

More Alodining, Machining Nylacast

 no activities

 March

Flap Drive

 March

Wingtip Rib

 no activities until July 2006

 March

Titanium, Baggage Compartment, Eclipse of the Moon

 März

Untere Motorhauben- Halbschale

 März Spur-Einstellung, Hauben-Abwurf, Tailtip 2, Tailtip 1, Bodenblech  März  März

 The Beginning

Setting up the workshop, waiting for the plans to arrive

April

More about Sonex Parts, the Stainless Instrument Panel, Corrosion-Story

 April

Hardware Kits Arrive, Glasscockpit, still more Priming

 April

New Engine under the Hood? Instrument Panel Takes Shape

April

A Flap Experience

 April

FI for Beginners, Thoughts...,

 no activities until July 2006

 April

all following entries in German Langauge!

Achsen, Fahrwerks-Beine, Belastungs-Test Gepäckfach

 April

keine Lust

 April

keine Aktivität

 April

Canopy-Finale

 April

 May

Wingrib gussets

 May

More on Tailcone, Priming, Improving the Sonex Design, Elevator Ribs, Compass

 May

NACA Vent, new Polish, Forward Fuselage, Secrets of the pulled dimpler and other dimpling tales

 May

Floor Stiffener, Polishing Pattern

 May

Flight Training, Canopy bow, Wingbolt- Placement

 May to July  no activities until July 2006

 Mai

das Ende? Motorträger, Fahrwerk I, Fahrwerk II

 Mai

mehr von der Cowling

 Mai TankInstallation

 Mai

nix

 Mai

 June

Working with stainless steel

 June

Polishing, Aileron Counterweights, Rear Spar and Other Problems

June

Small Jobs, Elevator Trim, Elevator Fuss, Bolting and Riveting, Forward Fuselage Sidewalls.

 

no building activities (too hot, no bolts available)

 June

more Wingbolt-Placement

Broke right leg during skydiving landing  no activities until July 2006

 Juni

Spornrad

 Juni

wieder keine Lust

 Juni

Flügel-Montage- Albtraum

 Juni

wieder nix

 Juni

 July

Wingrib production / big box arrives

July

Turtledeck goes to Junkjard, Inspector was here, Total Lift Indicator/Part One, Installing the Turtledeck Skin

Summer holidays, no significant homebuild acticities this month no building activities (too hot, no bolts available)

 July

Control Horn, Bronze Bushings, Pivot Blocks

no activities until July 2006

 July

Rigging left Aileron, Tiedown Bolts, Access Hole.

 Juli

Linearlager, erster Versuch

 Juli

zu warm

 Juli

Lackierereien,

der große BELASTUNGSTEST

 Juli

Belastungsversuch 2. und letzter Teil (gottseidank)

 Juli

 August

Angles and formblocks

August

More about AOA, Aileron Tip Ribs, Flaps, Rivet Squeezer, Split Turtledeck Skin, New Bulkhead #2?

 August

Elevator Trim completed

 August

New parts, engine ideas

 August

Stick Grip, Fixing the Wiggle, More of Control Horns and Sticks

 no activities until July 2006

August

Wing rigging

 August

Hauben-Rahmen

 August

Die Flügel sind dran (gottseidank)

 August

keine Aktivität

 August

Auspuff schweissen

 August

 September

More on bending, improved manufacturing methods

September

This'n That, More about Bending, Fuse Joints

 September

A Good Idea?, Summer Fly-In

 September

'Tight Fit' Holes are best ;-)

 September

Sparcap Bucking Bar, Mainspar, Wingbolthole, Wingbolt Drill Kit

 no activities until July 2006

 September

Wing assembly, Rotax vs. Lyncosaurs, Inspector was here

 September

Cockpit-Haube, Inchadder, gehärtete Welle trennen

 September

Linearlager - ein Flop

 September

Grundpolitur beendet

 September

Tailtips

 September

 October

Lightening holes & more bananas

October

Building an Engine Stand, Sparcaps

 October

Mounting Tail Tips, Vertical Tail, Aileron Counter- weight Fitting

 October

Mating the Fuselage Parts.

 October

Hard Working on the Wing, Sh.. happens, Wing Skeletal, Engine Rebuild, Mainspars accomplished!, Terrible Rivet

 no activities until July 2006

 October

Wire Conduits, Fairings, Strobe Light, The Whale

 Oktober Hauben- Abwurf- Mimik, Spornrad- Steuerung, Borhilfe, Brems-System

 Oktober

Horizontal- Trim- Steuerung, Strobe, Center- Konsole, Fairings

 Oktober

Kraftstoff-System, Abgasanlage, Kabinenhaube

 Oktober

Die Sonex wird ein Einsitzer, Propeller-Sachen

 Oktober

 November

Cockpit parts, bad holes, paint scheme

November

More about Sparcaps, Type 4 Disassembly

 November

Casting the aileron weights

 November

Tail Installation, This Engine Puzzles me. A Real Aviation Engine

 November

Wing Plumbing, Bushings

 no activities until July 2006

 November

Old Oklahoma Steamer, Closed the Wing End, Casting a Gasket, Lift Indicator Probe

 November

Fußspitzen- Pedale

 November

Platzprobleme unter der Haube, Gurte, Verdrahtung

 November

Kabinenhaube III, Kabinenhaube II, Kraftstoff_system II

 November  November

 December

The wooden bending brake, engine thoughts

December

Fine-Tuning the Wingribs, The Mirror-inverted Mainspar, Messing Up the Horizontal Tail

 December

Seat, Stick Grip, Idler and other pivot points, Glareshield Disaster, Instrument Panel No. 3

 December

Magneto

 December

Wingstuff, Aileron bellcranks

 no activities until July 2006

 December

Cowling Templates, Engine-Mounting, Breath of Time, @!?&%-Endrib, Problem Solving, Problems with the Left Wing

 Dezember Luftgekühlt, Nosebowl  Dezember Ölkühler-Anschluss, Überlegungen zum Vergaser

 Dezember

fliegt sie nun?

nee sie fliecht nich - zu kalt, zuviel Glühwein

 Dezember  Dezember