My Sonex Project
Posted: Fri Jan 24, 2020 4:22 pm
by Matt541
Wasn’t sure where would be best to post this, I didn’t build her, but I do have a decent list of things to do to get 541 flying again. As mentioned in my introduction thread, she’s currently in my garage with my old car holding the wings for me.
It did sit for a few years so I’m taking the time to go through it as well. Benefit of a small simple airplane is it shouldn’t take that long. (Knocks on my own head…)
The MUST DOs:
- New canopy and windscreen. The canopy was shattered when the POs hangar mate left the plane outside without it latched. Windscreen has multiple cracks both at mounting holes and in the bow shape.
- New tires and tubes. Good tread, but dry rot has definitely set in.
- Get the engine running. Seriously, I haven’t heard it run yet. Battery was dead, fuel was old, and the weather has been crap when I have free time. I did pull a few blades through before getting it.
- Fix one horizontal stab tip. It got damaged in the U-Haul on the way home, was tough to secure the tail and the truck didn’t help any. Used the interior pieces to cushion it, but still got some cracking.
- Repair canopy frame. When the wind took the canopy and shattered it, it also sheared the rear bow completely through. I’m going to attempt to repair it. But a new bow is cheap enough.
- Clean the heck out of it and take on polishing. It needs it!
The SHOULD dos:
- Install a transponder and ADS-B out. I’ve got an antenna on the belly, but nothing else. I’m really limiting my cross country options to the East without it. $$$
- Sand cracking spots and refinish the cowling. Extra dimples were added for the Revmaster engine and I’m seeing some cracking in the top coat.
- Modify and install wheel pants. The PO installed a nice set of O’ Keefe brakes, but never got to fly it with them. (Sorry dude.) Wheel pants haven’t been modified yet.
And the would be nice to do:
- Panel upgrade. Looking at different solutions to replace the “AveoMaxiSingles”, can’t find much about them online. Would be nice to integrate the transponder control into the EFIS. $$$
- Complete the warbird theme to complement the shark teeth already on the cowl. I love the look of the plane with them, just a bit plain still. Not going too crazy.
- Figure out a design for a baggage compartment. My airplane has a nicely upholstered cover over the turtle deck hole while the compartment is home to the smoke system tank. I’m from the school of thought that an airplane has to be able to carry something, even if it is just a flight bag or a tent and sleeping bag for fly ins. Sonex does give a pretty generous space back there, but weight limits and what not.
- Swing back canopy frame. All of the info I see on here for it references the ASA website, but that is currently a dead link. Anyone have more info on it?
- Finish the cabin heat. There is a heat muff installed, but nothing else. (Been following Mike Smith’s active thread.) Might just go with seat warmers, although I’m really digging the heated vest I got.
I’m sure more squawks will pop up as I work through the airplane. Hoping to have her ready for spring!
Re: My Sonex Project
Posted: Sat Jan 25, 2020 9:43 am
by DCASonex
Suggestion, just go ahead and completely replace the canopy frame. if old one was bent it will give you nothing but problems. A new one may be both faster and less expensive in long run.
If that engine has not run in a long time, a very complete inspection is needed at a minimum, and might consider tearing it down for a rebuild.
David A.
Re: My Sonex Project
Posted: Sat Jan 25, 2020 11:47 am
by Matt541
Those are both very good points, thanks David!
Looks like it’s new frame time then, didn’t consider that but it makes sense the way it broke that the front bow would be tweaked too.
The PO said the engine was last ran a few months ago, but who knows, time has a way of flying by. I plan on looking into it tomorrow, will pull the plugs and scope the cylinders.
Re: My Sonex Project
Posted: Sat Jan 25, 2020 2:48 pm
by GordonTurner
John Gillis “Fastj22” is the resident expert on the swing over canopy.
Re: My Sonex Project
Posted: Sat Jan 25, 2020 3:38 pm
by Sonex1517
I asked about swing back kits a year or more ago, and was told others had inquired and there would possibly be some available. I never heard back after that.
I’m still interested and I believe others are also. Let’s hope they become available again
Re: My Sonex Project
Posted: Thu Jan 30, 2020 7:27 pm
by Matt541
Thanks guys, I reached out to John about it and got some great feedback.
Also found that “rynoth” has an excellent write up about them on his blog: http://www.rynoth.com/wordpress/waiex/2015/03/10/general-fuselage-14-swing-back-canopy-completion/
Doesn’t seem to be too difficult…
Re: My Sonex Project
Posted: Thu Jan 30, 2020 7:31 pm
by Matt541
I’m not going to post every video I make, and fair warning it is kinda long.
But here is an overview video to go along with my project write up.
Re: My Sonex Project
Posted: Thu Jan 30, 2020 8:25 pm
by Rynoth
Matt541 wrote:Thanks guys, I reached out to John about it and got some great feedback.
Also found that “rynoth” has an excellent write up about them on his blog: http://www.rynoth.com/wordpress/waiex/2015/03/10/general-fuselage-14-swing-back-canopy-completion/
Doesn’t seem to be too difficult…
Yea unfortunately I see too that the link to the kit is dead… I still have the plans to assemble that kit but the plans don’t include dimensions for the provided parts. In particular the top-center swing arm is an aluminum welded part that I don’t have any idea how to reproduce/replicate.
Just to give you some warning and maybe some encouragement, I, along with many others, found the Canopy and the Engine cowl to be some of the most frustrating parts of the project. Mostly because of their custom nature, they become an arts-and-crafts project versus the more logical/linear nature of the rest of the build. I say this so that you don’t get discouraged, you have a tricky task ahead of you to replace the canopy but relatively speaking the rest of the airframe is more straightforward. Other than the powerplant, which is it’s own beast entirely.
Re: My Sonex Project
Posted: Fri Jan 31, 2020 10:38 am
by gyroron
keep the videos coming, I enjoyed the first one
Re: My Sonex Project
Posted: Fri Jan 31, 2020 6:35 pm
by Matt541
Thanks gyroron, that means a lot! I’ve got 2 more in the pipeline, hopefully upload this weekend.
Re: My Sonex Project
Posted: Fri Jan 31, 2020 6:47 pm
by Matt541
Rynoth wrote:
Just to give you some warning and maybe some encouragement, I, along with many others, found the Canopy and the Engine cowl to be some of the most frustrating parts of the project. Mostly because of their custom nature, they become an arts-and-crafts project versus the more logical/linear nature of the rest of the build. I say this so that you don’t get discouraged, you have a tricky task ahead of you to replace the canopy but relatively speaking the rest of the airframe is more straightforward. Other than the powerplant, which is it’s own beast entirely.
Not discouraged at all, I really appreciate the feedback from those that have gone before me. I’m definitely getting the impression that the canopy will be my least favorite part. I plan on using my oscillating tool to trim it, not too worried about cracking for that part. Drilling/ melting the holes and making sure everything lines up is another story.
Anybody fly a Sonex open cockpit? Just kidding, not designed for that I know. Flying a Schweitzer 300 with the doors off was pretty awesome though.
Re: My Sonex Project
Posted: Sat Feb 01, 2020 9:29 am
by Bryan Cotton
Matt,
Welcome to the group and congratulations on your new airplane.
Just to add a viewpoint on the canopy, I didn’t think it was that bad of a job. Like most jobs the fear of it going wrong is generally worse than the actual doing. My canopy went well also. My least favorite job was the baffling. We all have our bane.
All of my Schweizer time, glider or helicopter, was doors on or canopy closed. Most of my Enstrom time was doors off.
Re: My Sonex Project
Posted: Sat Feb 01, 2020 9:37 am
by Bryan Cotton
DCASonex wrote:Suggestion, just go ahead and completely replace the canopy frame. if old one was bent it will give you nothing but problems. A new one may be both faster and less expensive in long run.
If that engine has not run in a long time, a very complete inspection is needed at a minimum, and might consider tearing it down for a rebuild.
David A.
Once again I agree with David’s advice. If my canopy frame was damaged I’d replace it. The Aerovee is easy and fun to work on. We loved building it. Even if the engine turns out fine it is worth the educational experience for that particular engine.
Re: My Sonex Project
Posted: Mon Feb 03, 2020 2:35 pm
by racaldwell
If you need dimensions of the swingback canopy parts for the A style, let me know as I have those parts in the hangar. I finished mine. Here is a picture of the external keyed latch I made showing the lever inside that moves the slide lock on the pilot’s side.
Rick Caldwell
Xenos 0057
Re: My Sonex Project
Posted: Tue Feb 04, 2020 9:34 am
by Matt541
Bryan Cotton wrote:Matt,
Welcome to the group and congratulations on your new airplane.Like most jobs the fear of it going wrong is generally worse than the actual doing.
Some very wise and true words right there, and on more things than just airplanes. I am confident in my skills and the tools I’ll be using, but the unknown aspect of it is definitely a factor. All the what ifs…
Yup, the frame parts will be on my order from Sonex as well. I removed the frame from the airplane the other day. Laid it on level ground and could tell it how square it wasn’t anymore. I had already decided to heed the advice given, but that proved the point.
(How do you like the Enstrom? Most of the rotor options around here are either the Schweitzer or a Robinson. Did recently find someone with an Enstrom. Don’t have my add on yet, just a few training flights.)
Re: My Sonex Project
Posted: Tue Feb 04, 2020 9:37 am
by Matt541
racaldwell wrote:
Canopy Latch Closed Sm.jpg
If you need dimensions of the swingback canopy parts for the A style, let me know as I have those parts in the hangar. I finished mine. Here is a picture of the external keyed latch I made showing the lever inside that moves the slide lock on the pilot’s side.
Rick Caldwell
Xenos 0057
Excellent, thank you! Looks like yours is coming along nicely.
I’m going to order the canopy parts on my next payday and then figure out what I want to do. Every project I add pushes back the first take off…
Re: My Sonex Project
Posted: Tue Feb 04, 2020 9:42 am
by Matt541
Just re-uploaded my video on everyone’s favorite job… cleaning!
I promise it’s not just 6 minutes of some guy wiping down a plane. There is some commentary and time lapse too. It was just nice to watch her clean up and show her potential.
Re: My Sonex Project
Posted: Sat Feb 15, 2020 6:48 pm
by Matt541
The “latest” update on my project:
This actually occurred a few weeks ago, but did not get it edited and uploaded until today.
I learned quite a bit about my airplane though, need to make some changes to it’s “manual of arms.” The start flow well… doesn’t. Some of this is complicated by the hand brake lever on the stick. I’ll be using some sort of strap to hold the brakes on while starting to free up the hand. Probably move the throttle and starter button closer together so that can be done one handed.
My fuel shut off is on the other side of the panel, and like a fuel injected Arrow, the fuel has to be turned back on after the engine takes. Would be easier with the brake hand freed.
It’s really something to watch the prop turn the “wrong” way for a change though.
If you want to watch the video called “Will it Start?”…
SPOILER ALERT
It didn’t.
I just think it was still too cold that day, for as long as it’s been sitting. Regularly maintained and flown, I’m sure it would’ve fired right up. We didn’t bother to preheat it, will do so next time. Or wait for a nice sunny day. The way the weathers been up here, getting 3 different seasons in one week, it could happen. Until then, I’ve got a list of things to go over before hand. Not to mention all those other little projects.
Re: My Sonex Project
Posted: Tue Feb 18, 2020 12:02 pm
by Matt541
It was a beautiful 50°+ day here yesterday, so I opened up the garage door, and just sat in 541 for a bit.
Planning out what I’ll be doing with the panel, feeling out the muscle memory to be learned from the center, and may have played make believe with my own airplane noises…
Re: My Sonex Project
Posted: Tue Feb 18, 2020 12:22 pm
by Spark6
A worthy way to spend the day! Be sure to check for Zeros at your six-o-clock.
Re: My Sonex Project
Posted: Sun Feb 23, 2020 7:18 pm
by Matt541
It was a gorgeous day out again, well for “winter” in the NE. We rolled the plane out one more time to take a crack at getting it started again.
IT DID!
2nd or 3rd attempt, it was awesome!
All warmed up, no wings to fly…
Let it warm up, Ts&Ps all looked good. Did a couple run up sequences, then some short lived full power runs.
One step closer! Come on spring!
Not sure what that red “High Temp” light is connected to, Oil/ EGT/ CHT looked fine to me.
What numbers are you Aerovee guys looking for on the ground?
Re: My Sonex Project
Posted: Mon Feb 24, 2020 8:49 am
by GraemeSmith
Look in the copy of the flight manual I sent over for some acceptable temperature ranges for the AeroVee which are taken from the Sonex documentation. At all costs keep those CHT’s at the bottom end of the range. It’s tough when tightly cowled - the back two will get up there. Even on the ground on a warmer day. (PS - my documentation is in CELSIUS - so translate as necessary)
Re: My Sonex Project
Posted: Sat Feb 29, 2020 4:07 pm
by Matt541
Thanks again Graeme!
Finally got that video together on 541’s first engine start in who knows how long. (Yup, the Cessna jacket was carefully hidden away for this one!)
A big hurdle cleared, and we’re on to the next one. It’ll be spring before I know it!
Re: My Sonex Project
Posted: Tue Mar 17, 2020 6:22 pm
by Matt541
Quick update on my rehab project.
Finally built a wing holder over the weekend and got those wings off my car. We’ve already had some good cruising days…
Tires, tubes and LPS showed up at the doorstep today:
Pretty quick from the Spruce, ordered Saturday.
Just put in my order for the canopy, windscreen, and canopy frame bows today as well. Thanks for all the info and suggestions on that task!
And I finally decided to go ahead and order the AeroConversions throttle lever. The Revflow carb has a lever outside of the carb body unlike the AeroInjector. Currently have a push to open throttle, so will have to rig the cable from the other side as the the bottom of the lever pulls the cable. I did see where someone mounted a push cable above the pivot point, but… I dunno. Mark from Sonex also said I could use a bell crank to reverse the motion at the throttle linkage. Another option to be considered.
Finally getting into the more noticeable work of the project. Won’t be long now.
Re: My Sonex Project
Posted: Mon Mar 23, 2020 5:03 pm
by Matt541
Put a quick video together about where we’re at with 541.
Lots of new parts ready to go on, just need some of this 14 day lockdown time I keep hearing about to get things done.
Re: My Sonex Project
Posted: Sun Apr 05, 2020 12:02 pm
by Matt541
Got to spend some time with the plane yesterday after the virtual fly in.
Mocked up my baggage compartment with some cardboard and a plastic ammo can. Will be using ABS plastic sheeting next. We’ll see how that holds up. The can is big enough for a quart of oil, first aid kit, and some other necessities.
Getting things mocked up.
The whole can will be recessed into the tray, but still able to remove.
Re: My Sonex Project
Posted: Mon Apr 06, 2020 9:51 am
by Matt541
In case anyone is wondering, a Sonex canopy does fit in the back of a Jeep Cherokee…
My package arrived today from XPO, complete with canopy windscreen and frame hoops. Overall well packaged, doesn’t seem to be any damage. Nice work Sonex shipping team!
One corner of the windscreen did poke out of the shipper a bit, but it was handled properly by XPO. I see a lot of palletized and other bulk loads in my day job, was honestly expected more damage than I got.
So, if you need to order a new canopy and screen that’s being delivered in the US, fear not!
Re: My Sonex Project
Posted: Tue Apr 21, 2020 2:53 pm
by Matt541
Progress is slow, or at least it feels that way.
The biggest thing I accomplished this weekend was finishing the canopy frame with the added supports. They really do make a difference when opening the frame by itself. I hope it helps protect everything if a wind gust ever takes it again. Just have to remember to keep that canopy latched at all times.
Completed frame (until canopy fitting) and ABS sheeting for interior panels.
Doing some final fitting and structure for the ABS sheeting I’m using in my baggage compartment. This stuff cuts and forms pretty easily, yet has plenty of strength for it’s duty as a “hat rack.”
Experimenting with different length Southcos for the top bolts on the cowling. I like how they help with installing the halves when using the retainers. (As seen in Jeff Shultz’s video.) Everything I ordered from ACS was too short (140-180) using the clip on receptacles. Found some 82-19-320s on eBay and they actually fit 2 out of 3 holes on each side. This time I’ll grab the ACS catalog and and my caliper and get some better measurements. Nice to have some backups to the other places that use them though.
Should get tires swapped out this week.
Re: My Sonex Project
Posted: Wed Apr 22, 2020 9:57 am
by GordonTurner
Hi Matt
the ABS sheet looks interesting, looking for a material for a raised glare shield I am contemplating in order to increase the instrument panel size. I see it has good UV qualities and is available in sheets at reasonable price. For qualities, it is listed as STIFF. Since you’re working with it, can you tell me if a sheet has enough flexibility to curve over a light rounded structure to form the glare shield? Also, large sheets are available in 1/8 or 1/16 (or .25, .5, .75…) inch thicknesses. Do you have an opinion on how thin a sheet would work, no load on it but it should more or less retain smooth shape between supports…
Thanks for your expert opinion.
Gordon
Re: My Sonex Project
Posted: Thu Apr 23, 2020 9:56 am
by Matt541
Hi Gordon!
I won’t claim to be expert on ABS, even though I have a background in plastics, this was my first attempt at making larger interior panels with it.
This is the sheeting I used: https://www.amazon.com/gp/product/B07BX2BZDT/ref=ppx_yo_dt_b_asin_title_o09_s00?ie=UTF8&psc=1
Was only $15.45 for 2 sheets when I ordered, might want to wait for it to be back in stock or find another supplier.)
I went with 1/8" thickness as I felt 1/16" would be too thin. I’d probably stick with at least 1/8" for a glare shield. Of course thicker can be sourced too, but then you lose flexibility. ABS sheeting is commonly used for switch boxes and gauge clusters in motorsports. (Even more so before carbon fiber became more prevalent.) As a formed structure it is pretty stiff, but as sheet it can be flexed easily to make a curve. I actually have to flex it at a steeper angle to get my “hat rack” in and out. (Almost like Turn # 2 at Pocono.)
Edges can be easily formed using angle iron and a heat gun. Takes a bit to get to it’s forming temperature, above 220° F, but bends effortlessly once you’re there. You’ll know when. Try to get it right the first time though as I feel like multiple temperature cycles can cause warping of the surrounding areas. I don’t think you’d have a problem with it, but that property is something to be aware of for your intended purpose. Don’t think it would get hot enough to warp as a glare shield, but it will be getting direct sunlight through the windscreen and canopy.
ABS can also be “glued” to itself using MEK from your local hardware store. This is a good way to add structure or stand offs underneath. Probably a good idea since warping may be a concern.
It cuts easily with my Dremel (or any other brand) oscillating tool, same one and blade recommended for cutting canopies now. (I use mine for just about everything.) A jig saw or router work, but can be a bit much. Dialing in the right speed is key on both. Edges can be rough cut and then sanded down.
Another note, the sheeting comes with both a smooth side and a textured side. You’d probably want to leave the textured side out. The smooth side scratches more easily. I have scratched the textured side too, but it’s not easily noticed.
If nothing else, it’s a fairly easy and cost effective method to try.
