Updated: 23 Aug 20
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
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
Cold Air Induction
Jabiru 3300:
Jabiru Engine Switch
Cowling Modification
Going Places:
2008 Bartlesville Biplane Expo
The End of #604:
Forced Landing
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
Flight Test Like Your Life DEPENDS on it!
Flight Test Mechanics - A Simplified Approach
#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
"Coke-Bottle" Baffle Mods
#1374 Videos (YouTube):
My YouTube Channel
1374 Firewall Forward Tour
Installing the Vertical-Split Cowling
Low Fuel Monitoring Camera
1374 Walk-Around Tour
Jabiru 3300 Oil Change
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
How to fly a Saw-tooth Climb Test
#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
Oshkosh 2017
EAA's B-17
Reklaw 2017
#1374 Misc:
Thoughts on the AeroCarb, Revisited
Engine Monitor Data Analysis
Jabiru Starter Clutch Replacement
Best Mods and Features on Sonex 1374
Cylinder Inspection via Borescope (2018)
Borescope Inspection (2019)
#604 Downloads:
Plans Corrections (Word)
Builder Tips and Tricks (Word)
Line Drawings
Electrical System Diagram (Autocad)
N604X Condition Inspection Checklist
N604X Weight & Balance (Excel)
N604X Pilot Operating Handbook - AeroVee (Word)
(pdf)
N604X Specifications - AeroVee(Word)
AeroVee Assembly Manual: My Notes & Tips
AeroCarb Installation Tips from a Sonerai Builder
Sonex on their AeroCarb & AeroVee Engine
#1374 Downloads:
N604CM Weight and Balance Spreadsheet (Excel)
Fuel System Diagram (pdf)
Electrical System Diagram (pdf)
Simplified 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)
Control Stick Boot Pattern (pdf)