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Sonex Aircraft News Archive
September-October, 2012

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Sonex First Flight: John Cooley

Congratulations to John Cooley of Sugar Land, Texas whose standard gear, AeroVee powered Sonex (S/N 164) flew for the first time on October 28th! "Actual first flight was done on May 21, 2010 by Mike Singleton," writes John. "Then due to a series of life changing events my first flight did not occur until today, Oct. 28, 2012. Great flight and a great airplane. Many Thanks to my friend and neighbor Norm Kirby for all his help, guidance and assistance." Gold Wings are on the way to John!

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Waiex First Flight: Dick Harriman

Congratulations to Dick Harriman of Papillon, Nebraska whose tri-gear, AeroVee powered Waiex (S/N W0172) flew for the first time on October 20th! Dick built the aircraft with friend Michael Tabler. The pair, both retired Air Force pilots, completed their Waiex in only 10 months' time! "We felt our time spent at the Sonex Workshop was valuable, especially meeting the staff and being better able to connect with them when tech support was necessary." Gold Wings are on the way!

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Sonex Implements New Telephone System

Sonex Aircraft, LLC will implement a New Telephone System, beginning Tuesday, October 23rd. The new system features vastly-expanded capabilities to make call handling more efficient at Sonex, and to make the customer service experience better. We expect more customer calls to get-through to their intended destinations via our new telephone system, but please note that the size of our staff is still the same, so multiple calls to a single desk will not get through simultaneously.

The most noticeable change related to the new system that customers will experience is the use of a Main Menu when you first call Sonex. You may dial the number for your intended call destination at any time while the menu is playing. The menu options for the Sonex main telephone line (920-231-8297) are as-follows:

  1. Orders: Dial "1" if you have information and part numbers ready to place an order, or if you have an inquiry that does not fit within any of the descriptions below.
  2. Part Number Help: Dial "2" only if you have exhausted all other means of determining the part numbers you need. Before using this resource, be sure you have thoroughly checked your plans, packing lists, manuals and our web sites first. Alternatively, you can also email for help finding part numbers.
  3. Sales: If you are considering the purchase of a Sonex or AeroConversions product and are looking for additional information, press "3" to speak to a sales representative.
  4. Technical Support: If you are an existing customer and need technical support during your build, you can dial "4" and be connected to our Technical Support Staff during our normal tech support phone hours. You may also dial the Tech Line directly at 920-230-TECH (8324) or email
  5. Accounting: If you have questions about your account with Sonex Aircraft, LLC you may dial "5" to speak to a member of our Accounts Receivable team. You may also email your questions to
  6. Suppliers: Dial "6" if you are a supplier for Sonex Aircraft, LLC and you will be directed to our purchasing staff.

Sonex staff will be actively monitoring the health and performance of this new system over the coming days, weeks and months. Slight changes to the system's architecture may be made over-time to improve its performance, and the customer service experience. Permanent documentation of the system's current Main Menu structure can always be found on our Contacting Sonex web page.

Any and all comments and suggestions for improving this new telephone system, and the overall Sonex customer service experience, are always welcome! Please direct your comments and suggestions to Sonex Aircraft, LLC's General Manager, Mark Schaible, at

Read More about Contacting Sonex Staff!

Sonex Builders' Events:
ASA Holds 9th Annual Crossville Fly-In!

The American Sonex Association held its' 9th Annual Crossville, TN Fly-In last week, October 12-13th! The event was a huge success once again this year, despite some rainy weather across most of the country. 25 Sonex Aircraft were on-hand for the event and the crowds of current and prospective builders, their friends and families, topped 120. Attendees enjoyed great foot and camraderie, gathered for several builder-led seminars, and some flying. Door prized were awarded from Sonex Aircraft, LLC along with several other supporting companies. "Thanks to all the folks that came, and to the pilots that flew-in to show off their great aircraft," writes event organizer John Davis.

Sonex Aircraft, LLC would like to extend a huge thanks to John Davis and his crew, as well as all participating pilots & attendees for making this grass-roots Sonex builder event so successful again this year! You can find other events, or submit your own Sonex Builder Event to our Builders' Events Calendar!

See the Sonex Aircraft Builders' Events Calendar!

Sonex First Flight: John Maxfield

Congratulations to John Maxfield of Northville, Michigan whose standard gear, AeroVee powered Sonex (S/N 373) flew for the first time on October 16th! "Building it was great therapy," writes John. "Thank You, to the countless people that helped along the way, and especially to Kerry Fores in Tech Support and the entire Sonex Family." Gold Wings are on the way to John!

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New, Improved AeroConversions Oil Separator Now Available!


AeroConversions Oil Separator:

Sonex Aircraft, LLC is pleased to announce a new and improved version of the AeroConversions Oil Separator! The new, round AeroConversions Oil Separator features a higher-volume 40 oz. tank and a ball-bearing gravity changeover valve for enhanced aerobatic performance.

The AeroConversions Oil Separator is a high-quality welded and powder-coated aluminum assembly designed to save oil vs. direct overboard crankcase breathers in normal flight operations, and is a great way to keep the belly of your aircraft clean! The AeroConversions Oil Separator has provisions for both an overboard vapor breather/dump tube, as well as optional installation of an oil return line to the engine's oil sump, perfect for use with the AeroConversions Machined Oil Sump Plate. The AeroConversions Oil Separator allows oil to be retained and returned to the engine during short-duration inverted and negative G maneuvers.

Specifications: Total Oil Separator volume: 40 oz.; Volume held before overboard dump if no oil return line is installed: 33 oz. Diameter: 4 inches; Total Height: 7.5 inches. Breather Input and Oil Drain/Return Ports: 1/2-10 NPT. Vapor Port Out: 5/8" OD tube.

The AeroConversions Oil Separator ships with comprehensive installation instructions suitable for a wide-range of engine installations. AN fittings, hoses & clamps not included. See the AeroConversions Oil Separator Installation Instructions for more information.

See More AeroConversions Products!

Sonex Holds 52nd Builder Workshop Event!

Sonex Aircraft celebrated it's 52nd Sonex Builder's Workshop on October 6-7th, hosting another outstanding and group of current and prospective Sonex Aircraft builders! Attendees from across the country and around the globe traveled to Oshkosh to learn more about building, owning and flying Sonex Aircraft. The group constructed sample Sonex metalworking projects, received detailed informational sessions about all Sonex Aircraft designs, engine options, AeroConversions products, and all other aspects of building, owning and operating Sonex Aircraft.

Cooperative weather afforded an opportunity on Saturday and Sunday for several fly-by's of Sonex and Onex factory prototypes. Workshop attendees had the chance to inspect every inch of Sonex factory prototype aircraft, and try them on for size.

The Sonex Aircraft Workshop continues to be an extremely valuable experience for our builders, saving them time, money and answering many frequently asked questions in the building process. Sonex Builder Workshops are held several times per year at the Sonex Aircraft, LLC facilities in Oshkosh, WI, and significant kit discount incentives are offered for attendees. Our next Sonex Workshop will be held March 2-3, 2013. Sign-up Today!

Jeremy Monnett welcomes Workshop attendees, introduces the Sonex staff, and attendees introduce themselves to the group.

Jeremy performs a fly-by in the Sonex factory's Onex Single-Place, Folding-Wing Tri-Gear prototype.

Jeremy demonstrates the slow-speed capabilities of the Onex in a full-flaps pass.

John Monnett gives a walk-around tour of the Sonex detailing the design's key features.

Jeremy gives a tour of the Sonex warehouse, giving attendees a look at kit parts and packaging.

John demonstrates Sonex metalworking techniques to be used by attendees on their projects.

Workshop attendees get to work on their Sonex sample metalworking projects.

Some of Sonex's newer employees try their hands at the Workshop project. L to R: R&D Engineer Brian Rupnow, Warehouse Associate Ryan Grady, Warehouse Manager Steve Mitchell.

Jeremy assists a Workshop attendee in demonstrating solid riveting for the main wing spar using the Sonex bolt & hammer technique.

Sunday begins with more Sonex flying as Jeremy demonstrates the Sonex Sport Trainer prototype!

John details horizontal and vertical stablizer construction, with the aid of new Matched-Hole Formed Parts, in Sundays build tips session.

John gives tips for building Sonex Aircraft fuselage structures, squaring and skinning wing structures, working with plexiglass canopies and more on Sunday.

Read More about Sonex Builder Workshops!

Onex First Flight: Rheal Comte

Congratulations to Rheal Comte of Sainte-Hyacinthe, Quebec, Canada whose tri-gear, AeroVee powered Onex (S/N ONX0021) flew for the first time on October 9th! Gold Wings are on the way to Rheal!

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Sonex First Flight: Louis Charest

Congratulations to Louis Charest of Grande Prairie, Alberta, Canada whose standard gear, Jabiru 3300 powered Sonex (S/N 1384) flew for the first time on October 8th! Gold Wings are on the way to Louis!

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Sonex First Flight: Andrew Bink

Congratulations to Andrew Bink of Hernando, Mississippi who recently reported an August 7th first flight of his tri-gear, AeroVee powered Sonex (S/N 231)! Gold Wings are on the way to Andy!

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Onex First Flight: Merle Reppert

Congratulations to 3-time Sonex Aircraft builder Merle Reppert of Paradise, California whose tri-gear, AeroVee powered Onex (S/N ONX0049) flew for the first time on September 30th! "It flies great, a little faster than my AeroVee Sonex," writes Merle. "After failing the Air Force Cadet physical a long time ago, I finally got my fighter." Gold Wings are on the way!

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New from Sonex: Stratomaster iEFIS Explorer 8.5"


iEFIS Explorer Packages:

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Sonex Aircraft, LLC is pleased to announce the availability of the new Stratomaster iEFIS Explorer! The iEFIS Explorer is an 8.5" display in the new iEFIS line. iEFIS is the next generation EFIS system utilizing a custom developed, pressure sensitive, sunlight readable touch screen that can also be operated using gloves. iEFIS combines the undeniable advantages of simplified operation that a touch screen can offer with rich traditional controls which are equaly indispensible in the cockpit environment. The iEFIS Explorer includes a GPS receiver with moving map functionality, along with SP-6 and SP-7 Compass and Attitude Sensors as-standard!

The MGL iEFIS Explorer is also offered with the optional STX 165R Sandia Remote Encoding Transponder, which can be controlled by the iEFIS via the RS-232 port.

Find Out More about the Stratomaster iEFIS Explorer 8.5", as well as other Instrument Packages and Accessories offered by Sonex Aircraft, from our Instruments page.

Sonex First Flight: Harvey Plummer

Congratulations to Harvey Plummer of Fond du Lac, Wisconsin whose tri-gear, AeroVee powered Sonex (S/N 1010) flew for the first time on September 28th! "Thank you, Sonex for excellent plans," writes Harvey. Gold Wings are on the way!

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Sonex First Flight: Charles Clemen

Congratulations to Charles Clemen of Erie, Colorado whose standard gear, AeroVee powered Sonex (S/N 1223) flew for the first time on September 30th! "Thanks for all the help from everyone at Sonex," writes Chuck, "what a great airplane!" Gold Wings are on the way!

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See Sonex Matched-Hole Parts in Action:
New Videos Show Horizontal Tail Assembly!

Sonex Aircraft has produced two new videos showing the ease-of-construction added by the new Matched-Hole Formed Parts that are now a standard part of all Onex, Sonex and Waiex Kits!

Earlier this summer, Sonex CEO Jeremy Monnett spent 30 minutes with a video camera, tripod, and some Onex Tail Kit parts to capture the assembly of a Onex horizontal tail assembly on video. We've edited this footage to create an entertaining time lapse movie showing the tail being cleco'd together, while also creating a full-length narrative video of the assembly process. You can view both videos on the Matched-Hole Formed Parts web page.

Read More about Sonex Aircraft Kit Features!

Waiex First Flight: Lorin Miller

Congratulations to Lorin Miller of Colo, Iowa whose standard gear, Jabiru 3300 powered Waiex (S/N W0081) flew for the first time on September 23rd! "I really enjoyed the building process! Plans are outstanding and very understandable," writes Lorin. "The Jabiru 3300 ran strong, the performance level of the plane was absolutely stunning. I couldn’t have accomplished this project without the support of my wife and boys who put up with the nightly disappearances to the shop and hanger. My local EAA Chapter 675 and especially local Waiex builder/flyer Doug Boyd were invaluable resources, as well as great moral support. Scott Scheetz provided flight transition training in his Sonex, which I would highly recommend everybody get before their first flight. The transition training and preparation made it a non-event for me." Gold Wings are on the way to Lorin!

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Sonex First Flight: Mike Kelley

Congratulations to Mike Kelley of Lake Oswego, Oregon whose tri-gear, Jabiru 3300 powered Sonex (S/N 1284) flew for the first time on September 20th! "Being just a few miles from Van’s factory, there have been a lot of RV builders watching my hanger activity over the past month. I think there are several jealous RV-12 builders after seeing my Sonex fly!" writes Mike. "Even after flying Grummans and Mooneys for years, I was blown away by the rapid acceleration of the Sonex as I fed the fuel to the Jab on the initial takeoff. Great job Sonex design team! This is my first project and I want to give special thanks to my wife and family who supported me throughout this 1151 hour build." Gold Wings are on the way to Mike!

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Sonex First Flight: Jorge Ortiz Arceo

Congratulations to Jorge Ortiz Arceo of Morelia Michoacan, Mexico who recently reported the June 6, 2012 first flight of his tri-gear, Jabiru 3300 powered Sonex (S/N 1131)! "I am very proud to be a member of the World Wide Sonex Fleet," writes Jorge. "Thanks to all Sonex family, and to all people who helped this dream to come true." Gold Wings are on the way!

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Sonex First Flight: Jose Manuel Diaz Cuervo

Congratulations to Jose Manuel Diaz Cuervo of Asturias, Spain whose standard gear, Jabiru 3300 powered Sonex (S/N 880) flew for the first time on September 19th! Gold Wings are on the way!

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Waiex First Flight: Michael Stout

Congratulations to Michael Stout of Pt. Payne, Alabama whose standard gear, Jabiru 3300 powered Waiex (S/N W0125) flew for the first time on September 9th! "On Sunday 9/9/12 Waiex Ser# 125 stopped being an assemblage of airplane parts, and became an airplane!" writes Michael. "The Jabiru 3300 practically threw it into the air before the pilot (me) had a chance to get a deep breath. Didn't matter, I wasn't breathing anyway! Thank you to my fantastic wife who made this not only possible, but enjoyable, to Jackie Bailey, my tech advisor from EAA Chapter 890, and to Kerry Fores, and Jeremy Monnett, whose responsiveness, and good advice, kept me on track. Great airplane!" Gold Wings are on the way to Michael!

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Waiex First Flight: Marlin Zimmerman

Congratulations to Marlin Zimmerman of Muscoda, Wisconsin whose standard gear, AeroVee powered Waiex (S/N W0105) flew for the first time on September 5th! Gold Wings are on the way!

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