Sonex #604
& Sonex #1374
Jeff Shultz

Updated: 1 Mar 17



   Home
   What's New
   Check out my YouTube Channel
   SonexFlight Podcast

Preparation:
   Why a Sonex?
   Workshop
   Tools
   Tools 2
   Plans and Materials
   The Kit Arrives
   Workbench
   Build Philosophy
   Corrosion Protection

First Parts:
   Angle Stock
   Cutting Interior Curves
   Forming a Typical Part
   Using the Vixen File

Fuselage:
   Fuselage Parts
   Dimpling and Countersinking
   Forward Fuselage
   Aft Fuselage
   Turtledeck
   Joining the Fuselage
   Firewall
   Spar Carry-thru
   Cockpit Details
   Landing Gear
   Gear Fairings
   Wheels & Brakes
   Panel Planning
   Other Builder's Panels
   Glareshield
   Instrument Panel
   Seat
   Controls
   Battery Box
   Electrical System
   Canopy

Tail:
   Vertical Stab
   Bending the Stab Spar
   Horizontal Stab
   Elevators
   Rudder
   Fiberglass Tips
   Attaching the Tail
   Tail Fairings

Wing:
   Flaps
   Ailerons
   Rear Spars
   Ribs
   Main Spars
   Riveting the Spar
   Spar Mating
   Wing Assembly
   Aft Wing Skins
   Leading Edge Skins
   Aileron Bellcrank
   Misc Details
   Deburing and Riveting
   Wingtips
   Rigging

Engine:
   AeroVee Assembly 1
   AeroVee Assembly 2
   AeroVee Assembly 3
   Installation
   Fuel System
   Cowling
   Baffles
   Fire Barrier Paint

Finishing:
   Paint Schemes
   Painting the Interior
   Wheel Pants
   Painting the Aircraft
   Final Assembly
   First Flight

Misc:
   Rivets and Hardware
   Baggage Compartment
   Cockpit Vents
   Insulation
   Armaments
   Sonex Links
   Other Builder's Panels
   Registering Your Homebuilt
   Lessons Learned


After First Flight

Flight Testing:
   What's Been Happening the Past Year?
   Engine Troubles
   Engine Timing
   Improving Engine Cooling
   Engine Tuning Lessons Learned
   Trim Tabs
   Calculating Percent Power
   Those Horrible Slide Carbs!
   Reshaping The AeroCarb Fuel Needle

Modifications:
   EIS Interference
   Engine Pre-Heater
   Angle of Attack Meter
   Misc Mods

AeroVee Modifications:
   New Fence Baffles
   K&N Air Filter
   Oil Cooler Inlet Reduction
   Engine Breather Vent
   Cold Air Induction

Jabiru 3300:
   Jabiru Engine Switch
   Cowling Modification


Going Places:
   2008 Bartlesville Biplane Expo


The End of #604:
   Forced Landing


The Next Chapter

Sonex #1374:
   New Beginnings
   Fuselage
   Vents
   Controls
   Brakes
   Canopy
   Panel
   Interior
   Tail Fairing
   Firewall
   Engine and Baffles
   Cowling
   Final Assembly
   N604CM: What's in a Name?

Flight Testing:
   Climb Testing for Vx & Vy
   Dynon Data Log Analysis
   Climb Performance Charts
   ASI Calibration
   Prop Comparison
   Takeoff and Landing Distance
   Tuning the AeroCarb:
My Method

   Leaning the Jabiru


#1374 Mods:
   Intersection Fairings
   Landing Gear Leg Stiffeners
   1374 Gets Paint!
   Aux Fuel Tank
   Low Fuel Monitoring Camera
   Electric Seat Heaters
   Modified Cowl Outlets
   AoA on the Dynon Skyview


#1374 Videos (YouTube):
   My YouTube Channel
   1374 Firewall Forward Tour
   Installing the Vertical-Split Cowling
   Low Fuel Monitoring Camera
   1374 Walk-Around Tour
   Sonex Acro
   Oshkosh 2016 Adventure
   How I operate My AeroCarb
   GoPro Vibe-X Wingtip Camera Mount
   Additional Firewall Forward Details
   MGL V6 Radio Settings in my Sonex


#1374 Events:
   2014 Mile High Fly-In
   2014 KFLY Ultralight & Light Sport Gathering
   2015 Mile High Fly-In
   KITPLANES Newsline: SNF 2016
   Reklaw 2016
   2016 Kansas City "Turkey-Shoot"
   2017 Mile High Fly-In


#1374 Misc:
   Thoughts on the AeroCarb, Revisited
   Engine Monitor Data Analysis
   Jabiru Starter Clutch Replacement
   Best Mods and Features on Sonex 1374


#604 Downloads:
   Flyby Video (.wmv)
   Plans Comments (Word)
   Builder's Sites Notes (Word)
   Line Drawings
   Electrical System Diagram (Autocad)
   N604X Condition Inspection Checklist
   N604X Weight & Balance (Excel)
   N604X Pilot Operating Handbook - AeroVee (Word)
   N604X Specifications - AeroVee(Word)
   AeroVee Assembly Manual: My Notes & Tips
   AeroCarb Installation Tips from a Sonerai Builder
   Sonex on their AeroCarb & AeroVee Engine
   AeroConversions Margarita Maker


#1374 Downloads:
   N604CM Weight and Balance Spreadsheet (Excel)
   Fuel System Diagram (pdf)
   Electrical System Diagram (pdf)
   Jeff's Flight Testing Spreadsheet (Excel)
   Sonex Vx-Vy Flight Testing Spreadsheet (Excel)
   Sonex Vy Climb Testing Spreadsheet (Excel)
   ASI Calibration Spreadsheet (Excel)
   Takeoff and Landing Distance Spreadsheet (Excel)
   N604CM Pilot Operating Handbook - Jabiru 3300 (Word)
   N604CM Specifications (Word)
   N604CM Condition Inspection Checklist
   Checklist Cards (word)
   Dynon Skyview Checklist File (txt)


Copywrite © 2004-2016
Jeff Shultz