Sonex #318

Tools and Shop

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Tools and Shop
Tail Feathers
Flaps and Ailerons
Spars
Wing Skins
Ribs
Wing Assembly
Forward Fuse - Assy
AFT Fuse-Side Panels
AFT Fuse-Assy
Final Fuse-Assy
Cockpit
Engine
Event Photos
First Flight

My current "shop" is the right half of my 4 car garage.  Don't get me wrong I have little to complain about.  I just miss my previous shop where I didn't have to worry about who was sleeping above me when I turned power tools on.

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My famous "Pole Brake"  detailed drawings are available email me at weber.sonex@verizon.net.  This is the easiest way to make bend in the thick aluminum stock.  Make sure you make your bends aggressively. If you go too slow the metal will work harden and the part will crack before you can complete the bend.  Small adjustments after the initial bend are not a problem.

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download Pole Brake Assembly file

 
 
Just a normal 9" Delta Band Saw purchased for under $100 using a blade that I bought from DoAll.  4 bi-metal blades cost me $40 and they cut the aluminum like butter.
 
CONSTRUCTION TIP!
Make or purchase two guides for the table of your band saw.  Clamp them as shown to cut those long pieces and you will have perfect, repeatable cuts every time,but use stonger clamps than I have pictures here.  This was how the Wright bothers cut their material.  THIS WORKS! USE IT!

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I have recently added a 12" disk sander which is a much better tool than the Royi 6".  I don't even use the Roybi any more.

 
 
To get the rivet puller into some tight spaces I made a small stand-off out of a bolt shank. Just drill a hole down the center and you're good to go.  Bruce Harrington who is much brighter than me simply used an R/C airplane wheel collar.  Wish I would have thought of that!
 

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For placing parts that can not be clamped well or held in place by any other positive locking manner I go with the double back tape.  Make sure you purchase the thinnest type you can with a very high tack.  I use the 3M VHB #4335.  This was invaluable during the fuselage construction.  Buy it and use it!

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