Building Sonex Shed part 2

Second part of the shed build. Will it stop raining? I have made more mess than what I am building, but slowiy getting there, and shed formwork is taking shape
#shed
#buildingworks
#sonex
#kitplane
#shedtime
#experimentalaircraftchannel
#aeroplane
#garage
#sonexaircraft

[@gonegliding2966]

New sheds are always a good thing!

[@pandyseven]

Sheds are the best, and can’t wait for this to be finished, just have to get past the rain, think we have had 15 or so days of it…

[@dan_der_flieger]

Looking good Andy. Here's the question everyone's asking: Pockets or Bailey - which one contributed more to the work being done in this video? 🙂

[@pandyseven]

Definitely Baily, he is out there with me rain hail or shine. Pockets is just another 19-year-old, he has a lot to learn in life.

[@andrewschmidt5312]

I was watching your previous build videos - impressive work. I am considering a future build and after watching you and Gavin (hope he is ok, not seen any videos) the Sonex price and construction look very appealing. Thank you for showing your build - great information. One thing bothers me about these homebuilt kits. Why do they send them with all the rivet holes drilled undersized? Have to spend (waste?) time redrilling and deburring all of them. Why doesn’t the factory drill to the correct final size? Thank you in advance.

[@dan_der_flieger]

​@@andrewschmidt5312Andy can probably shed light on this too, but I think it comes down to kit cost. Many of the parts are not drilled at all and you use the smaller holes to pilot drill into undrilled metal first and then up-drill to a 1/8" hole once the pilot holes are aligned. Vans (makers of the RV series of aircraft) recently had an issue where they outsourced parts to a 3rd party that laser cut some parts. My understanding is that they did it incorrectly and the pre-drilled holes became overheated, changing the temper of the alloy, which would lead to cracking where the rivet was placed. With the Sonex kit needing to be up-drilled by hand, that doesn't happen (unless you use a really dull drill bit).

[@pandyseven]

Hi Andrew, I believe Gavin is just caught up with domestic duties at his B&B but will reach out to him today just in case, also Dan der Fieger. Rivet holes are undersized basically to allow you time to set out your project, it’s a way to assembly and should you be out with a hole just a bit, were it does not quite line up, you get a second go, so silver to copper cleco scenario. That said kits come in many options; some are laser holed. There are, I believe, a good and bad side to the laser, as it hardens the surface and has potential, and I say potential to stress fracture with subsequent failure. I believe RV aircraft manufacturer had some previous issues, but don’t quote me. Aircraft have been built the way Sonex do it for years back to WW2 and beyond that, for me it’s a proven method. Sonex do laser hole but they are so small its just to align the 3/32 drill head up, but laser it in this scenario a perfect way to align multiple parts up, eg spars [ ruddervators] Kit manufacturers are going for fast build options and hence the holes being predrilled in say skin surfaces, my first plane I built we had to measure out everything so the predrill size worked a treat. I totally love stainless pop rivet and makes for a faster build. The only thing I would do again differently would be choose a kit that offered instrument wiring full harness and instrument options, something I wish Sonex offered. I am working my way through the instruments with help, so I hope this helps you and others, please email anytime hope I have given some good food for thought. Regards Andy

[@andrewschmidt5312]

⁠​⁠@@dan_der_flieger and @pandyseven thank you both very much for your detailed replies . Greatly appreciated! It makes sense. Its great when knowledgeable people take the time to educate others.