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Please notify Sonex Aircraft, LLC of any errors at: tech@sonexaircraft.com

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General - All Airframe Models

Service Bulletins: All Airframes

Status

Models and Serial Numbers Date of Issue Reference Number Description
REQUIRED Jabiru 3300 Tri-Gear Configurations (This includes all aircraft fitted with motor mount part numbers SNX-P22-02 or SNX-P22-08. 08.24.11 SNX-SB-007

Description:
Sonex Aircraft has received reports of the tri-gear Jabiru 3300 engine mounts breaking where the outer tube interfaces with the triangular bracket that supports the nose gear strut.

Mandatory Inspection:
All tri-gear Jabiru 3300 motor mounts must be checked prior to your next flight with a particular emphasis on the area where the tubes interface with the triangular nose strut gusset. This should be continuously checked at regular intervals after that, such as at oil changes, 25, 50, and 100 hour inspections and during the Condition (Annual) Inspection.

This area must also be inspected immediately if nose wheel vibration is detected, a hard landing is experienced, after rough field operation, or if the nose strut is stressed sideways from improper ground handling.

Any crack found must be repaired prior to your next flight.

Optional Corrective Action:
Sonex Aircraft has upgraded all new production Tri-Gear Jabiru 3300 motor mounts (identified on the plans, on packing lists, and by part label as part number SNX-P22-10) to include an additional tube. This tube, made of 3/4” diameter x .035” wall 4130 steel tubing can be added to all existing motor mounts.

Registered Sonex aircraft owners can contact Sonex Aircraft at tech@sonexaircraft.com and request a free tube, part number SNX-P22-07, which can be welded to your motor mount after removing the engine.

The tube must be welded in place using accepted aircraft welding and repair practices.

Ongoing Inspection:
Modified motor mounts must be inspected at regular intervals, such as at oil changes, 25, 50, and 100 hour inspections, and during the Condition (Annual) Inspection.

See diagram with full service bulletin text in download: SNX-SB-007-TRI-3300_Motor_Mount_Change.pdf

Jabiru 3300 Tri Gear Motor Mount Tube Installation instruction sheet: Jab_3300_Mount_Tube_Installation.pdf

REQUIRED All Sonex, Waiex and Xenos Aircraft. 06.28.11 SNX-SB-006

Sonex Aircraft has received 4 reports of the stainless steel bolts that secure the gear legs in standard gear motormounts breaking inside the titanium gear leg. All affected aircraft have logged more than 20 hours and/or more than 25 landings on turf runways. To date there have been no reports of bolt breakage on aircraft operated on paved runways. Three of the four reports have been on aircraft operating on rough runways.

Additionally, over-tightening of the nuts may have contributed to these failures.

Mandatory Inspection:
Prior to each flight inspect all stainless steel bolts securing the gear legs in the motormount (standard gear) or gear mount brackets (tri-gear), as well as the stainless steel bolts that secure the axles to the landing gear legs. Minimum inspection requirement is to try to turn each bolt with a wrench, observing the nut for similar movement. The bolts must be replaced with “steel” AN hardware prior to flight if there is any indication of a failed bolt. If both the bolt and the nut turn together DO NOT TIGHTEN the nut. This is acceptable until the hardware can be replaced.

Mandatory Corrective Action:
As soon as possible, replace all stainless steel bolts with drilled “steel” AN bolts of equivalent size, and replace the AN365 elastic stop nuts with AN310-4 castle nuts and MS24665-208 cotter.

Main Gear Installation:
AN4C-30A Bolt is replaced by AN4-30 Bolt (drilled)
AN4C-17 Bolt is replaced by AN4-17 Bolt (drilled)
AN365-428 Nut is replaced by AN310-4 Castle Nut and MS24665-208 Cotter Pin

Tail Wheel Installation:
AN4C-12A Bolt is replaced by AN4-12 Bolt (drilled)
AN365-428 Nut is replaced by AN310-4 Castle Nut and MS24665-208 Cotter Pin

Install the castle nut by tightening it until it is snug and then loosen the castle nut 1/4 to 1/2 turn before installing the cotter pin. Do not over-tighten the castle nuts on installation.

Proper bolt sizes can be found in the “L” section of the aircraft blueprints. Example: Sonex drawing SNX-L01, Detail A, AN4C-17 bolts and AN365-428 nuts to be replaced by AN4-17 bolts, AN310-4 Castle nuts, and MS MS24665-208 cotter pin.

Ongoing Inspection:
After the hardware has been replaced with drilled “steel” AN hardware and castle nuts, the inspection shall be conducted at each Condition Inspection of the aircraft.

Download Printable PDF File: SNX-SB-006-Gear Leg Bolts-Change.pdf

REQUIRED All Sonex, Waiex and Xenos Aircraft. 11.02.09 SNX-SB-005

Sonex Aircraft has changed the wall thickness of the two lower support tubes on all motor mounts from 0.035” to 0.049”. The two lower support tubes run from the lower motor mount pins to the lower fuselage motor mount attachments.
WAS: 3/4" Diameter x .035 Wall 4130 Steel Tube
IS: 3/4" Diameter x .049 Wall 4130 Steel Tube

All motor mounts shipped from Sonex since June of 2005 have this heavier-wall tubing already installed on the motor mount. These are identified on packing lists and labeled with -08 part numbers.

In over 11 years of service (and currently 279 completions), Sonex Aircraft has received a total of 4 reports of motor mount support tubes breaking between the lower motor mount pin and the welded area that picks up the cross-tubes. 2 of these reports were on 3300 Jabiru Engine Std Gear Mounts and 2 of these reports were on 2200 Jabiru Engine Std Gear Mounts. In all 4 cases, these were found during inspections and were obvious with a visual inspection.

All Sonex, Waiex, and Xenos Aircraft that do not have -08 motor mounts installed shall visually inspect the area of the motor mount pins for cracks prior to next flight and at regular intervals not to exceed 25 hours of flight time. If area shows signs of cracks the aircraft shall be taken out of service until suitable repairs have been made.

(update 12.04.09) Alternatively, customers may purchase and install a new -08 motor mount, or make the following upgrade/repair to their existing mount: SNX-Mount-Repair.pdf

REQUIRED All Sonex and Waiex Tri-Gear Aircraft purchased
before May 1st, 2007
07.03.07 SNX-SB-004

SNX-C02-10 NOSEWHEEL PUSH ROD SPRING CHECK:
Sonex Aircraft has discovered that some Sonex and Waiex Kits Shipped before May 1st, 2007 may have included the incorrect Nosewheel Push Rod Springs. All Sonex and Waiex Tri-Gear Aircraft Owners should inspect their Sonex-supplied SNX-C02-10 Springs to ensure they are correct.

A correct Nosewheel Push Rod Spring Installation looks like this: SNXC0210_Correct.jpg

An incorrect Nosewheel Push Rod Spring Installation looks like this: SNXC0210_InCorrect.jpg

If your Sonex Supplied SNX-C02-10 Springs are not installed yet, you may measure the inside diameter to determine if they are correct or not. The correct springs measure over 0.60" on the inside diameter: SNXC0210_Correct_Measure.jpg

The incorrect springs measure under 0.60" on the inside diameter: SNXC0210_InCorrect_Measure.jpg

If you determine that you do not have the correct SNX-C02-10, please send an e-mail to the Sonex Tech Department at: tech@sonexaircraft.com. An RMA Number will then be issued for the return and inspection of the incorrect parts. If found to be the incorrect parts, replacements will be sent to you at no charge.

REQUIRED
All Flying Sonex Aircraft
8.22.05
SNX-SB-002

CHECK ALL WELDED COMPONENTS FOR CRACKS IMMEDIATELY:
All Welded Components should be checked prior to your next flight with a particular emphasis on the motor mounts in the area of the lower mount pin attach points. These should be continuously checked at regular intervals after that, such as at Oil Changes, 25, 50, 100, 500 hour inspections and at Annual Inspection.

Note: A crack in your black powder-coated welded component will show as a bright white/gray line and any separation of the structure will be visible to the naked eye. A flashlight and magnifying glass should be used to assist in the inspection.

Any crack found must be repaired prior to your next flight.


Sonex

Service Bulletins: Sonex Airframes

Status

Models and Serial Numbers Date of Issue Reference Number Description
OPTIONAL
All Sonex Aircraft
11.21.05
SNX-SB-003

UPGRADE OF SNX-F10-03 ANGLE:
The upper portion of the Seat Belt Cross-Tie Assembly (SNX-F10-03) is made from SNX-Z02-03 Channel Stock. Sonex,ltd suggests that SNX-F10-03 be replaced in all Sonex aircraft with a piece fabricated from 1"x1"x1/8" thick 6061-T6 Angle. This replacement part is installed in the same location and has the same fit and function as the original SNX-F10-03. It strengthens the lower seat attach area especially for those choosing to install the Lowered Seat Modification. The new part number for this piece is SNX-F10-26.

Note: This service bulletin does not apply to the Waiex or Xenos.

REQUIRED
All Flying Sonex Aircraft
8.22.05
SNX-SB-002

CHECK ALL WELDED COMPONENTS FOR CRACKS IMMEDIATELY:
All Welded Components should be checked prior to your next flight with a particular emphasis on the motor mounts in the area of the lower mount pin attach points. These should be continuously checked at regular intervals after that, such as at Oil Changes, 25, 50, 100, 500 hour inspections and at Annual Inspection.

Note: A crack in your black powder-coated welded component will show as a bright white/gray line and any separation of the structure will be visible to the naked eye. A flashlight and magnifying glass should be used to assist in the inspection.

Any crack found must be repaired prior to your next flight.

REQUIRED
All Sonex Aircraft with SNX-C02-01 Rudder Pedal Assemblies
6.07.02
SNX-SB-001
(3 pages)
Sonex Rudder Pedal Service Check and Upgrade or Replacment:
Download all 3 pages of SNX-SB-001 in Adobe .pdf Format Below:
SNX-SB-001p1.pdf (Page 1)
SNX-SB-001p2.pdf (Page 2)
SNX-SB-001p3.pdf (Page 3)

 

Waiex

Service Bulletins: Waiex Airframes

Status

Models and Serial Numbers Date of Issue Reference Number Description
REQUIRED ALL WAIEX AIRCRAFT 08.21.14 WIX-SB-002

Description:
Sonex Aircraft has received reports of the supplied swaged cables for P/N's WIX-C04-01 and WIX-C04-03 are not 1/16" proud of the Nicopress Sleeve. See Assembly Instruction #10 on the attached cable control prints:

Download: WIX-C04-01-FwdRudderCable.pdf

Download: WIX-C04-03-AftRudderCable.pdf

Image of correct Nicopress Sleeve and Thimble Installation - Download: WIX-SB-002-Cable_Swage_Inspection.pdf

Note that a cable installed flush with the end of the Nicopress Sleeve is serviceable and does not present a safety hazard.

Mandatory Inspection:
All P/Ns WIX-C04-01 and WIX-C04-03 must be checked prior to your next flight for compliance with the Sonex Assembly Instructions.

Required Corrective Action:
The Registered Waiex Owner must do four things to qualify for warranty replacement:

  1. Go to: WIX-SB-002 Waiex Cable Service Bulletin Replacement Parts on the Sonex Web Store to register/place replacement parts order.
  2. Sonex must receive a picture of the incorrect cable(s) with the part numbers identified by e-mail at tech@sonexaircraft.com. The subject line of the email to the Tech Department Must reference the Service Bulletin Number as well as the web store order number. (If customer elects not to email a photo, the customer may return the cables to Sonex at their expense. Should the returned cable(s) be deemed in proper condition, the cable(s) will be returned to the customer at their expense. Return instructions listed on the Sonex Web Store.) Please note: no action will be taken by Sonex until step one and two have been completed by the customer.
  3. Sonex will confirm there is (or is not) a problem with a response to your e-mail.
  4. To avoid being charged for the cable(s), customers must either submit a photo of the cables cut in two just below the incorrect swage OR return the incorrect cables, at their expense, to Sonex to be destroyed.

Note: Flying aircraft will be given shipping priority.

REQUIRED
ALL WAIEX AIRCRAFT (Sonex Airframe Model NOT included in this Service Notice)
11.15.11
WIX-SB-001

This Mandatory Service Notice details the addition of 3 aluminum structural components to the Waiex Tail/Fuselage attachment.
Download: WIX-SB-001_drawing.pdf

History:
Sonex Aircraft, LLC conducted a design review applying a different design load criteria than was originally defined and complied with in FAR part 23. As a result of this review the design team determined this Service Notice of Modification was necessary to enhance and ensure the continued safety of the Waiex fleet.

Warning:
All Waiex Aircraft flights done without complying with this Service Notice are AT YOUR OWN RISK!

Service Parts:
Sonex Aircraft, LLC is sending all Waiex Kit Customers the parts necessary to install this structural upgrade at no cost as soon as possible.

 

Xenos

Service Bulletins: Xenos Airframes

Status

Models and Serial Numbers Date of Issue Reference Number Description
REQUIRED ALL XENOS AIRCRAFT 08.21.14 XNS-SB-002

Description:
Sonex Aircraft has received reports of the supplied swaged cables for P/N's XNS-C04-02 and XNS-C04-07 may not be 1/16" proud of the Nicopress Sleeve. See Assembly Instruction #10 on the attached cable control prints:

Download: XNS-C04-02-FwdRudderCable.pdf

Download: XNS-C04-07-AftRudderCable.pdf

Image of correct Nicopress Sleeve and Thimble Installation - Download: XNS-SB-002-Cable_Swage_Inspection.pdf

Note that a cable installed flush with the end of the Nicopress Sleeve is serviceable and does not present a safety hazard.

Mandatory Inspection:
All P/N’s XNS-C04-02 and XNS-C04-07 must be checked prior to your next flight for compliance with the Sonex Assembly Instructions.

Required Corrective Action:
The Registered Xenos Owner must do four things to qualify for warranty replacement:

  1. Go to: XNS-SB-002 Waiex Cable Service Bulletin Replacement Parts on the Sonex Web Store to register/place replacement parts order.
  2. Sonex must receive a picture of the incorrect cable(s) with the part numbers identified by e-mail at tech@sonexaircraft.com. The subject line of the email to the Tech Department Must reference the Service Bulletin Number as well as the web store order number. (If customer elects not to email a photo, the customer may return the cables to Sonex at their expense. Should the returned cable(s) be deemed in proper condition, the cable(s) will be returned to the customer at their expense. Return instructions listed on the Sonex Web Store.) Please note: no action will be taken by Sonex until step one and two have been completed by the customer.
  3. Sonex will confirm there is (or is not) a problem with a response to your e-mail.
  4. To avoid being charged for the cable(s), customers must either submit a photo of the cables cut in two just below the incorrect swage OR return the incorrect cables, at their expense, to Sonex to be destroyed.

Note: Flying aircraft will be given shipping priority.

REQUIRED
ALL XENOS AIRCRAFT (Sonex Airframe Model NOT included in this Service Notice)
11.15.11
XNS-SB-001

This Mandatory Service Notice details the addition of an aluminum structural component to the XenosTail/Fuselage attachment.
Download: XNS-SB-001_drawing.pdf

History:
Sonex Aircraft, LLC conducted a design review applying a different design load criteria than was originally defined and complied with in FAR part 23. As a result of this review the design team determined this Service Notice of Modification was necessary to enhance and ensure the continued safety of the Xenos fleet.

Warning:
All Xenos Aircraft flights done without complying with this Service Notice are AT YOUR OWN RISK!

Service Parts:
Sonex Aircraft, LLC is sending all Xenos Kit Customers the parts necessary to install this structural upgrade at no cost as soon as possible.

 

SubSonex

Service Bulletins: SubSonex Airframes

Status

Models and Serial Numbers Date of Issue Reference Number Description
REQUIRED SUBSONEX (Serial Number 0003 to and including 0012) 06.13.17 JSX-SN-002

Nose Wheel Fork Set Screw Installation – Mandatory Inspection

Drawing JSX-L02 (Rev D and prior) depicts a set screw (callout number 5, part number JSX-L02-42) that MUST engage the hole in the Clevis Pin (callout 42, part number AN394-53). Further, the set screw must be Locktited in place.

Failure of the set screw to engage the clevis pin can result in separation of the nose fork assembly. Drawing JSX-L02 has been revised (Rev E and above) to more clearly illustrate the installation of the set screw. A JPEG of the revision can be viewed here: Download: JSX-L02_Rev_E_Detail.jpg

If your SubSonex is licensed, this modification must be completed before your next flight and documented in your airframe’s logbook.

REQUIRED All SUBSONEX Airframes Delivered Prior to June 13, 2017 (s/n 0001 to and including s/n 0012). 06.13.17 JSX-SB-001

Control System Collar Roll Pin Installation – Mandatory Service Bulletin

Sonex Aircraft have identified the need to pin the control pushrod collars to the pushrod (JSX-C03-02). Failure to do so can result in the collars moving on the pushrod if the bolts come loose, resulting in loss of positive control of the control surfaces. The linked drawing shows the modification and identifies the size of the roll pin used. A copy of this drawing and two roll pins have been mailed to each affected airframe. This modification must be completed before your next flight and documented in your airframe’s logbook.

Download: JSX-SFC01_Roll_Pin_Install.jpg

AeroConversions Service Bulletins

Service Bulletins for all AeroConversions products can be found at the following pages on the AeroConversions web site:

AeroVee Engine Kit

AeroInjector/AeroCarb


 

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