SONEX CONDITION INSPECTION CHECKLIST

AIRCRAFT: _______ Sonex, SN _______

REGISTRATION: N________

ENGINE: __________, SN __________

PROPELLER: __________, SN __________

(This Annual) (Last Annual)

DATE: _________________ ________________

TT AIRFRAME: _________________ ________________

TT ENGINE: _________________ ________________

TT PROPELLER: _________________ ________________

Inspection Item	SAT	UNSAT	Notes
General:
Registration/Airworthiness/Operation Limitations Present
Aircraft Identification Plates Installed
All Cockpit Placards and Labels are Installed and Legible
Experimental & Passenger Warning Placards Installed
Weight and Balance/Equipment List Present
Skyview Updated with Latest Software, Database and Maps
Wash airplane. Remove all oil/grease from belly and inside cowling. Remove interior upholstery. Clean interior, cockpit floor, under-seat area, and baggage area.
Propeller:
Check Spinner for Condition and Security
Inspect Prop for Cracks, Nicks/Stone Damage, or Delamination
Check Prop Hub Area for Crushing, Water Damage, Delamination or Burning. Inspect Bolts, Bolt Holes and Bushings every 200 hrs.
Re-torque Prop Bolts to 17 +/-3 ft-lbs (200 +/-20 in-lbs)
Check Prop Tracking (Max 1/8” off at tips)
Rebalance Prop After Making Any Repairs
Replace Prop Flange Cap Screws every 500 hrs; Torque Cap Screws to 30 ft-lbs.
Engine:
Perform Periodic Maintenance per Jabiru Maintenance Manual
Warm Engine until Oil Temp is 90-100 deg F
Perform Compression Test (engine warm) #1______ #2_______ #3______ #4______#5______ #6______
Drain and Replace Oil (3.25-3.5 qts, + Optional 3-4 oz Cam Guard)
Replace Oil Filter (Cut Open and Check for Metal); Torque Filter Hand Tight
Inspect Engine for Leaks at all Seals, Sensors, and Gaskets
Inspect Cylinders for Cracks/Broken Fins/Exhaust Stains
Check Exhaust Pipes/Flanges/System for Security, Attachment and Condition; Torque Attachment Screws to 8 ft-lbs
Inspect Front Crankcase Seal for Damage or Leaks
Inspect Engine Case, Accessory, and Mounting Bolt Torque
Inspect Engine Mount/Bushings
Inspect Oil Recovery Bottle and Engine Breather Line
Inspect Intake Manifold and Manifold-Intake Tube Seals for Security/Leaks
Check Rubber Intake Tube Couplers for Heat Damage, Cracking, and Security
Inspect Magnetrons for Mounting Security, Heat Damage (Discoloration), Frayed Spark Plug Lead and P-Lead Condition
Inspect Ignition and Wiring Harness, Cap and Boots for Condition and Continuity
Clean and Gap Spark Plugs (NGK D9EA) to 0.022-0.024”, Apply Anti-seize Lube and Torque to 8 ft-lbs (72 in-lbs)
Remove Rocker Chamber Covers; Inspect Rocker Arms, Pushrods, Valve Stems, Valve Springs; Note Oil Color, Quantity, and Evidence of Carbon Blow-by in Valve Guides
Inspect Engine Baffles and Gull Wing Inter-cylinder Baffles for Cracks/Condition
Inspect Oil Cooler, Cooler Flanges and Mounting Brackets, Oil Filter Adapter (Donut), Oil Lines, and Oil Pressure Sensor
Inspect Carburetor, Rubber Boot, and Clamps for Condition and Security
Inspect Throttle & Mixture Controls for Proper Travel, Cable for Cracks or Kinks, Loose Hardware, and Overall Security
Clean and Re-oil K&N Air Filter (K&N Recharge Kit)
Check Cowling for Cracks, Chaffing, Heat Damage and Security; Remove All Oil and Residue
Inspect Cowling SouthCo, Receptacles and Mounting Plates
Replace Flywheel Bolts every 500 hrs
Electrical:
--Firewall Side--
Battery (Security, Mount, Cables, Free of Corrosion)
Battery Box (Security, Mounts and Corrosion)
Relays (Battery Contactor, Alternator Disconnect, Starter Relay, all Diodes)
Filter Capacitor (Wires, Screws, Mount, Condition of Capacitor)
Alternator (Stator) AC Leads, PIDG Terminals for Burning/Corrosion, and AC Wire-Loom Covering
Wiring Harness Loom, Sensor Wire Bundles, and Firewall Pass Thru Points
Rectifier/Regulator (Condition, Corrosion, Heat Damage, Connector, Terminals, Wires, Mounts); Re-grease with Dow DP4 Dielectric Grease
Fuses, Fuse Blocks, and Wiring for Condition and Security
Grounding System (Cables, Grounding Block, Terminals, Main Engine Ground Cable) for Condition and Security
--Cabin Side--
Visually Inspect Under Panel for Loose Wires, Chaffing or Damage
Switches for Secure Mounting, Secure Terminals, Evidence of Arcing and Proper Operation
12v Accessory Sockets for Security and Proper Operation
Seat Warmer Switches, Wiring, and Heating Pads for Chaffing, Overheating and Proper Operation
Fuel System:
--Firewall Side--
Fuel Cap and Rubber Plug for Condition, Operation, Chemical Damage and Secure Fitting
Fuel Tank Vent System (Obstructions, Damaged Rubber Coupler, Secure Clamps, Kinked Drain Tube)
Filler Neck Drip Pan (Sealant Degradation, Leaks, Alignment)
Fuel Placard Properly Legible and Affixed to Fuel Cover Door
Fuel Line for Chafing/Leaks/Security/Condition
Inspect Quick Drain Valve (Mounting Security, Leaks or Damage)
Draw Fuel Sample to Check for Water and Contaminants (4-8 oz); Test for Ethanol Content: Ethanol = ________ %
Disassemble and Clean Fuel Filter Internal Screen
Fuel Line Heat Shielding, Reflective Tape, and Insulation
--Cabin Side--
Leaks, Weeping Fittings, Corrosion, Contamination Under Panel
Shutoff Valve, Bowden Cable Pull Lever, Cable Clamp and Cable Attachment Bracket
Flow Sender for Leaks or Damaged Wiring
Fuel Line Under Panel for Chafing/Leaks/Security/Condition
Aux Fuel Intake Hose, Molded-in Tank Fitting, Check Valve, and Fuel Hose Pigtail for Leaks, Damage, and Security
Low-Fuel Monitoring Camera for Mounting Security, Alignment, Tank Markings, Tank LED Lights
Fuselage:
--Outside--
Fire Wall for Distortion, Cracks, Missing RTV Sealant at Edges, or Degraded Firewall Penetrations
Cowl Mounting Hinges (Excessive Wear or Damage)
Lose/Smoking Rivets, Lose Bolts, Cracked Skin
Fuselage Splice Plate Bolts for Looseness or Evidence of Movement in Joint
--Inside--
Canopy Latching Mechanism for Damage, Cracked Plexiglas, Missing Spring, Legible Placard Installed
Instruments, Pitot/Static/AoA Lines, Labels and Marking for Condition and Security
Remove Seat (Cushions and Seat Pan) and Inspection Covers
Wing Attach Bolts, Mounting Angles, and Adjacent Skin for Deformation, Cracks, Missing Hardware, Security
Seats, Seat Belts/Shoulder Harness for Security and Attachment
Upholstery (Condition, Velcro Security, Cleanliness, Seat Warmers and Wiring)
Inspect and Service ELT (Clean/Replace Batteries, Antenna Cable, Mounting Tray) (Bat Exp Date:__________________)
COMM, ELT and Transponder Antennas (Security, Corrosion, Proper Grounding); Re-lube with DP4
Rudder Pedals for Cracks, Operation and Security of Bolts/Cotter Pins, Fraying or Kinks in Cables
Flap Control Operation and Bolts for Security
Control Stick for Wear, Freedom of Movement, and Security of Bolts/Cotter Pins
Lube Control Triangle Bushings and Elevator Pushrod Link and Bellcrank Bushings (LPS-1)
Baggage Compartment Sides and Floor for Cleanliness, Condition and Security
Rear Spar Carry Thru for Condition, Wear, and Security of Bolts
Remote Transponder, Connector, Antenna and Mounting Tray
Elevator Pushrod Support Snap Bushings for Wear, Security and Condition; Lube Bushings with White Lithium Grease
Landing Gear:
Remove Wheel Pants and Gear Fairings
Wheel Pants for Cracks, Damaged or Elongated Holes, Stripped Nutplates
Gear Leg and Intersection Fairings for Cracks or Excessive Wear
Gear Leg Stiffeners for Delamination, Cracked Fiberglass and Broken Wood Inserts
Wheel Pant Mounting Plate (Cracks, Loose Bolts, Alignment)
Inspect Wheel Alignment and Tire Wear Pattern
Wheels/Tires for Cracks, Tread Depth and Serviceability
Jack up Fuselage and Remove Wheels; Inspect Gear Leg Upper Bolts (AN4-33A) and Axel Socket Lower Bolts (AN4-16A); Replace every 500 hrs
Inspect Brake System for Air Bubbles or Loss of Fluid Pressure
Remove Brake Calipers, Wheels and Bearings
Verify Brake Pucks are within Limits
Brake Discs for Wear, Rust, Warping, Damaged/Missing Hardware
Brake Lines for Chaffing or Cracking
Axle Weldments and Mounting Tabs for Cracks, Corrosion, Elongated Holes
Wheel Bearings, Remove Old Grease, Repack with Automotive Wheel Bearing Grease
Replenish Fluid in Brake Master Cylinder; Bleed as Needed using Dexron VI ATF (Alternate ATF Fluid: Type A, Dexron II/III, Mercon V)
Check Tire Pressure; Fill to 40 psi
Re-install Wheel Pants and Fairings; Loctite (blue) All Fasteners; Use New MS24693C273 (aka AN507C1032R10) 1032 x 5/8” Flush Stainless Steel Machine Screws (12 Total) and AN525-10R11 Screws (2 Total)
Wings:
Remove Inspection Plates/Fairings
General Inspection of the Exterior/Interior of Wing
Popped Rivets/Cracked/Deformed Skin
Wingtips for Lose Rivets, Cracked Fiberglass
Flap/Aileron Attachment (No Play or Slop)
Aileron Bellcrank for Wear, Security
Flight Control Hinges/Rod End Bearings/Bellcranks (Check for Binding and Excessive Wear)
Corrosion (Internal Skins, Front and Rear Spars)
Flight Control Bolts/Pins for Safety and Condition
Lube Rod Ends, Hinges and Bushings (LPS-1)
Pitot/Static Probe for Obstructions, Security, Tubing Connections; AoA Port Rivet for Obstruction, Security, and Tube Connection
Empennage:
Remove Inspection Plates and Tail Fairing
Inspect Vertical Fin and Stabilizer Attach Points (Under Fairing Bolts, Tail Post Bolts, Horizontal Stab Bolts)
Inspect Elevator Trim Tab (Cable Wire, Hinge, Attachment Hole, Free Play)
Inspect Rudder Control Cables (Fraying, Ends, Attachment Bolts)
Inspect and Lube Elevator Pushrod Rod End (LPS-1)
Inspect Fiberglass Tail Tips (Cracks, Scuffs, Security)
Inspect Fiberglass Tail Fairing (Cracks, Stripped Screw Holes)
Inspect Tail Wheel Pushrod (Cracks, Damaged Rod Ends or Threads)
Clean and Lube Tail Wheel Bearings and Pivot Arm
Inspect Tail Wheel for Tire Wear, Rotate Orientation as Needed
Operational Inspection:
Visual Inspection of the Engine/Propeller/Cowling
All Inspection Panels and Fairings Secure
Proper Fuel In Tanks
Idle Rpm/Mixture Check
Static RPM (Run-up) Check: Idle RPM____________ WOT RPM_________ Oil Temp ________ Oil Press ________
Logbook Entry and Signoff:
Record All Findings, Repairs and/or Work Performed and Sign off Inspection and Maintenance In Aircraft Log Books. “I certify that this aircraft has been inspected on ________ in accordance with the scope and detail of appendix D to part 43, and was found to be in a condition for safe operation. Signed _______________, A&P/Repairman # “

I hereby certify that all requirements in this annual condition inspection report have been met, and I have determined the aircraft to by airworthy.

Signature _______________________________________________ Certificate # (A&P or Repairman) .

Notes:

Maintenance Data

Oil 20W-50 or 15W-50 Multigrade, (Phillips XC 20W-50, AeroShell 15W-50)

W100 Ashless, Dispersant

Oil Capacity 3.0 – 3.5 qts

Oil Filter Fram Extended Guard XG4967 Napa Gold 1394

Bosch 3311 Purolator L14476 (or PER4476)

Royal Purple 10-2840 Baldwin B33

K&N HP-1003 Mobile 1 M1-103

Air Cleaner K&N RU-0630

Coil Gap 0.010” - 0.012”

Spark Plugs 12mm NGK D9EA

Spark Plug Gap 0.022” - 0.024”

Torque Data

Prop Bolts AN6 17 ft-lbs (+/- 2)

Rocker Cover Cap Screws 1/4" 6 ft-lbs

Valve Chamber 1/8 NPT Plug 5 ft-lbs

Cylinder Head 5/16” 20 ft-lbs, 24 ft-lbs (new)

Intake / Exhaust Cap Screws 1/4" 8 ft-lbs

Spark Plugs 11/16” 8-10 ft-lbs

Flywheel Bolts 5/16” 32 ft-lbs

3/8” 36 ft-lbs

Alternator / Coil Bolts 1/4” 8 ft-lbs

Crankcase Cap Screws 1/4" 10 ft-lbs

Crankcase Main Studs 3/8” 30 ft-lbs

7/16” 35 ft-lbs

Oil Drain Plug 1/2” 14 ft-lbs

Starter Motor Bolts 1/4” 8 ft-lbs

Operational Data

Max RPM 3300 rpm (3200 rpm static)

Idle RPM 800-1000 rpm

CHT Range 250-350º F (396º F Max)

EGT Range 1200-1375º F (1450º F Max)

Oil Pressure 33-76 psi (40-60 psi cruise)

Oil Temp 160-220º F (175-195º F Cruise)

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Download the Annual Condition Checklist (word), (pdf)