Starting
8/31/2018: The plans are reviewed and the intial webbing is clamped together with the sonex spacing tool between the spars to ensure proper alignment.
Drilling Commences
9/1/2018: Once the webbing is clecod in place, the drilling starts. Everything is pilot drilled at 3/32".
Pilot Drilling Complete
9/1/2018: The pilot drilling using the Sonex spacing tool and reference pilto holes on the skin is very helpful.
Different Types of Rivets
9/21/2018: There are many different rivet types used int he wing spar. Each one was assigned a color code and an "F" indicated that the web needs to be formed for flush rivets.
Countersinking
10/3/2018: The thicker solid webbing needed to be countersunk precisely. It came out pretty good and matches the plan's specifications.
Flush Solid Rivets
10/3/2018: Here I started installing flush solid rivets in the spar. Using the bucking bar as the flat source and a bolt and mallet to crush the rivet in place.
Horrible First Timer
11/27/2018: The first spar took me forever and this is why, I had a lot of trouble with the solid rivets. These all were drilled out and tried again. The second time around was better.
Lots of Riveting Left
11/27/2018: There are so many rivets to do, it is easy to get discouraged but you need to stick with it.
Rounded Heads
11/28/2018: The rounded head solid rivets were easier to install with an air rivet gun and the SOnex bucking bar.
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Round Rivets Done
11/30/2018: The round rivets were completed on the right spar.
Right Spar Done
12/11/2019: The right spar is finally completed. Now to start the left one!
Left Spar Started
12/12/2018: The left spar is clamped and spaced using the Sonex spacing tool, drilling to commence in the spars.
Pilot Holes Complete
12/12/2018: All the pilot holes were successfully drilled through the spars.
Aux Fuel Tanks!
1/31/2019: Happy New Year. Took a break from building the spars to enjoy the holidays and work on the house. The auxiliary fuel tanks arrived today!
Back to Building!
2/7/2019: Ok break time is over and time to start getting back to the grindstone. Updrilling the pilot holes and getting ready for rivets.
Countersinking Left Spar
2/8/2019: Countersinking the spars, and the thick webbing. Getting ready for assembly and rivets.
Solid Rivets!
2/9/2019: Finally pounding solid rivets into the left spar. Make sure to download and use the Sonex spar supplement on their website.
Both Spars Done
2/12/2019: Both spars are completed. They look fantastic!
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Wing Spars Clamped
2/13/2019: The wing spars need to be clamped and aligned in order to drill out for later wing rigging.
Nice Alignment
2/13/2019: The alignment was perfect although it was a little difficult to do this by myself.
Long Wingspan
2/13/2019: I was surprised at how long the wingspan is even with the overlap of spars.
It's Long!!
2/13/2019: Thats what she said...ok enough with the jokes, time for the scar part of drilling out the mounting holes to 1/2" diameter.
Bolts Fit!
2/13/2019: Well the bolts fit tightly, thats a great sign that I must have done it right.
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THE WING SPARS

Updated: 5/5/2019

© 2017-2019 Timothy Wrede

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Aircraft Photos Used by Sonex Aircraft, LLC.

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