Drive Horn 0:15

I just received my Amazon order for a digital protractor. After receiving it, the instructions listed the read out granularity was 0.1 while the accuracy was only 0.3 deg. Great, I guess you get what you pay for. In the end I doubt 0.3 deg will amount to much other than an imperceptible amount of clearance. Either way, I checked the measurements against a mechanical protractor and .2 deg is just guess work at that point. Completed bending the horn by pressing it into a piece of ash wood I cut to 8deg on my bandsaw. Then testing and adjusting with my digital protractor.

Drive Horn 2:00

Well I got started building the plane again, after several years and three moves. What better place to start than rebuilding the rudder. I was not happy with how the first one came out. So, build it again I will. Step one create a new drive horn. I still have to drill holes and what not. But it was fun to make some progress no matter how small.

Fiberglass Tail Tips 4:00

I spent 4 hours finishing up the fiberglass work for the tail tips and installing them. Not a lot to talk about. I spent a lot of time considering the rudder. After discussing the off set the rudder has with my EAA chapter and Sonex tech support, I’m going to go ahead and rebuild the rudder. Not a lot of work now, but after paint it would be a real pain.

Elevator 0:30

While I was at Oshkosh this year, I spent lot of time inspecting the tail section of Sonex aircraft. I know there is a joke here, somewhere. Well, the thing I noticed the most was that several of them had a slight twist in the elevator. Some worse than others. While they were all flying just fine, I’d still like to try and avoid this. So today I upgraded my workbench to make it as flat as I could get it. I snugged down the 2x6s as good as I could, then added a thick slab of MDF. Flatter than plywood and easily replaceable.


I then laid out the parts to start the Elevator and spent some time reading the plans. Sometimes I wish the plans included best practices/techniques for building a particular part.

Horizontal Stab 2:00

I’ve heard that the secret to completing a large build like this is to spend at least 5 minutes a day in the shop. Well I have some lost time to make up. I lined up the hinge to connect the elevator to the horizontal stabilizer, clamped and drilled the holes. Then I spent a lot of time up-drilling the skin. That was a lot of holes and moving the clecos got tedious. I changed hands on the pliers many times. I’m well on my way to Popeye arms. I always think the skin looks cool when you put the #30 clecos in place and before you remove the #40 clecos. Right now I only have 200 #30 and 200 #40 clecos, and I’m using every one of them. I should really order more.