Sonex -- The Sport Aircraft Reality Check!
B-Model Home AeroConversions Home Sonex Home Sonex Home
 

SONEX
WAIEX
XENOS
ONEX
SUBSONEX
AeroVee
AeroConversions Accessories
Sonex Video Tips
Subscribe to the Sonex Drawing Rev/Service Bulletin RSS Feed

Video Topics:

Tools | Material - Sheet Metal | Material - Extruded Angle | Material - Plate Stock | Material - Titanium | Material - Plexiglass | Drilling & Riveting | Kit Parts Preparation | Finishing | AeroVee | Flight Test | Scratch Building


Tools:

Sonex Recommended Tools 3-Part Series

Sonex Aircraft, LLC now has a 3-part video series discussing the tools recommended to build a Sonex, Waiex or Xenos. For a complete listing of tools recommended to build Sonex Aircraft, see the Sonex Required Tools Page.


Cleco 101


Click to Watch Video

 

Charlie Becker of EAA tells you everything you need to know about Cleco temporary fasteners.


Super Simple Dimple Die


Click to Watch Video

 

Jeremy Monnett of Sonex Aircraft demonstrates how to dimple sheet aluminum to accept countersunk rivets using Sonex Aircraft, LLC's Super Simple Dimple Die.


Homemade Dimpling Tool


Click to Watch Video

 

John Monnett shares how to make a homemade, simple dimpling tool that works great in tight places. Also be sure to check-out the Sonex Super Simple Dimple Die.


Torque Wrench Basics


Click to Watch Video

 

Torque wrenches are often used in aircraft construction, particularly when building your AeroVee Engine Kit. Jeremy Monnett of Sonex Aircraft discusses the two most common styles of torque wrenches available and how they work.


Video Topics:

Tools | Material - Sheet Metal | Material - Extruded Angle | Material - Plate Stock | Material - Titanium | Material - Plexiglass | Drilling & Riveting | Kit Parts Preparation | Finishing | AeroVee | Flight Test | Scratch Building


Material - Sheet Metal:

Cutting with Metal Snips


Click to Watch Video

Although most parts in a Sonex Aircraft kit come pre-cut, using snips to properly cut sheet metal is still an important homebuilding skill that you will need.

This video demonstrates the techniques for cutting out a wing rib blank for those who are scratch-building, but the basic skills apply for all builders. See the whole series, "Making a Sheet Metal Rib from scratch" under the Scratch Building topic area.

Note: Pre-Formed Ribs and Bulkheads are included in all Sonex Aircraft Kits!


Using a Fly Cutter to Cut Holes in Sheet Metal


Click to Watch Video

Although most parts in a Sonex Aircraft kit come pre-cut, using a fly cutter is a skill that even full kit builders may need to cut inspection holes, etc.

This video demonstrates the techniques for using a fly cutter to cut a lightening holes in a sheet metal wing rib blank, for those who are scratch building. See the whole series, "Making a Sheet Metal Rib from scratch" under the Scratch Building topic area.

Note: Pre-Formed Ribs and Bulkheads are included in all Sonex Aircraft Kits!


Video Topics:

Tools | Material - Sheet Metal | Material - Extruded Angle | Material - Plate Stock | Material - Titanium | Material - Plexiglass | Drilling & Riveting | Kit Parts Preparation | Finishing | AeroVee | Flight Test | Scratch Building


Material - Extruded Angle:

Cutting Aluminum Using a Bandsaw


Click to Watch Video

 

Thicker sections of aluminum, such as extruded aluminum angle and bar stock, are best cut on a bandsaw with a wood cutting blade. Kerry Fores of Sonex Aircraft demonstrates the proper techniques.


Filing Aluminum


Click to Watch Video

 

A vixen file is ideal for rapid removal of aluminum, brass, copper and hard rubber. In this video, Jeremy Monnett of Sonex Aircraft demonstrates using a vixen file to clean up a piece of extruded aluminum angle cut on a bandsaw.


Aluminum Angle Adjustment


Click to Watch Video

 

Sonex Aircraft Chief Flight Instrutor and EAA Flight Advisor and Technical Counselor Joe Norris demonstrates how to make small adjustments to change the 90 degree angle in 6061-T6 aluminum angle.


Closing Aluminum Angle


Click to Watch Video

 

This video tip features Sonex Aircraft, LLC employee Kerry Fores demonstrating techniques for reducing the angle of 90 degree extruded aluminum angle stock.


Bending Aluminum Angle with a Wrench


Click to Watch Video

 

Sometimes you will need to change the bend on a piece of extruded aluminum angle. In this video, Jeremy Monnett of Sonex Aircraft shows how this can be done with a large adjustable wrench.


Video Topics:

Tools | Material - Sheet Metal | Material - Extruded Angle | Material - Plate Stock | Material - Titanium | Material - Plexiglass | Drilling & Riveting | Kit Parts Preparation | Finishing | AeroVee | Flight Test | Scratch Building


Material - Plate Stock:

Bending Aluminum Plate with an Arbor Press


Click to Watch Video

 

This video tip features Sonex Aircraft, LLC employee Kerry Fores demonstrating the technique for using an arbor press to bend thick sheet metal.


Video Topics:

Tools | Material - Sheet Metal | Material - Extruded Angle | Material - Plate Stock | Material - Titanium | Material - Plexiglass | Drilling & Riveting | Kit Parts Preparation | Finishing | AeroVee | Flight Test | Scratch Building


Material - Titanium:

Drilling Titanium Gear Legs


Click to Watch Video

 

This video tip features Sonex Aircraft, LLC employee Kerry Fores demonstrating techniques for drilling Sonex Aircraft Titanium Gear Legs.


Video Topics:

Tools | Material - Sheet Metal | Material - Extruded Angle | Material - Plate Stock | Material - Titanium | Material - Plexiglass | Drilling & Riveting | Kit Parts Preparation | Finishing | AeroVee | Flight Test | Scratch Building


Material - Plexiglass:

Drilling Holes in Plexiglas


Click to Watch Video

 

In this segment, John Monnett shares how to modify a drill bit to drill Plexiglas without cracking. Note that Sonex Aircraft kits all feature SonPlex acrylic canopies, which have a rubber additive for increased durability.


Drilling Holes in Plexiglas Using a Unibit (Step Drill)


Click to Watch Video

 

EAA Technical Counselor and Sonex Aircraft Chief Flight Instructor and Director of Fleet Maintenance Joe Norris demonstrates how to drill holes in acrylic parts such as a canopy using a unibit step drill.


Cutting and Fitting a Sonex Aircraft Canopy


Click to Watch Video

 

In this segment, John Monnett, founder of Sonex Aircraft, LLC, shows the basic steps of cutting and fitting a canopy on a Sonex Aircraft. Note that Sonex Aircraft kits all feature SonPlex acrylic canopies, which have a rubber additive for increased durability.


Video Topics:

Tools | Material - Sheet Metal | Material - Extruded Angle | Material - Plate Stock | Material - Titanium | Material - Plexiglass | Drilling & Riveting | Kit Parts Preparation | Finishing | AeroVee | Flight Test | Scratch Building


Drilling & Riveting:

Solid Riveting Sonex Aircraft Main Spars with a Bolt and Hammer


Click to Watch Video

 

Joe Norris demonstrates the "Bolt and Hammer" method for driving the 5/32" diameter AD solid rivets used in Sonex Aircraft main wing spars. This technique is considered a safer technique for novice builders, and eliminates the need for expensive riveting equipment.

Note: Pre-Assembled Main Wing Spars are available for all Sonex kits, eliminating the need for builders to do any solid riveting!


Drilling Piano Hinges


Click to Watch Video

 

Piano Hinges are used everywhere on Sonex Aircraft for their strength, ease of installation, and easy assembly/disassembly. Charlie Becker of EAA demonstrates the Sonex technique for rapidly measuring and drilling piano hinge rivet holes.


Drilling in Tight Places


Click to Watch Video

 

Sometimes you simply can't get a drill into place to drill a hole. In this episode, Charlie Becker of the EAA staff shows some ways to drill in tight places.


Pull Riveting in Tight Places


Click to Watch Video

 

Charlie Becker of EAA describes his special techniques for installing blind rivets in tight places.


Cleco 101


Click to Watch Video

 

Charlie Becker of EAA tells you everything you need to know about Cleco temporary fasteners.


Drilling Titanium Gear Legs


Click to Watch Video

 

This video tip features Sonex Aircraft, LLC employee Kerry Fores demonstrating techniques for drilling Sonex Aircraft Titanium Gear Legs.


Drilling-Out a Rivet (Blind Rivets Demonstrated)


Click to Watch Video

 

Joe Norris of EAA demonstrates the proper technique for drilling-out blind rivets.


Drilling-Out a Driven Rivet


Click to Watch Video

 

Jack Dueck of the EAA Homebuilders' Council demonstrates the proper techniques for drilling-out solid driven rivets.


Video Topics:

Tools | Material - Sheet Metal | Material - Extruded Angle | Material - Plate Stock | Material - Titanium | Material - Plexiglass | Drilling & Riveting | Kit Parts Preparation | Finishing | AeroVee | Flight Test | Scratch Building


Kit Parts Preparation:

Blue Lining a Rib for Installation


Click to Watch Video

 

The use of a "blue line" mark makes installation of a sheet metal rib very easy. In this video, Kerry Fores shows you this handy technique.


Removing Powder Coating


Click to Watch Video

 

This video tip discusses removal of powder coating from Sonex Aircraft kit welded components in areas contacted by bearing surfaces.


Preparing Rotationally Molded Fuel Tanks for Installation


Click to Watch Video

 

This video tip discusses preparation of Sonex Aircraft Rotationaly Molded Cross-Linked Polyethelyne Fuel Tanks for installation. There is also a full set of downloadable Fuel Tank Installation Tips available on our Instruction Sheets page. For those that have trouble with preparation of their fuel tank fittings, Sonex Oops Fittings are available.


Video Topics:

Tools | Material - Sheet Metal | Material - Extruded Angle | Material - Plate Stock | Material - Titanium | Material - Plexiglass | Drilling & Riveting | Kit Parts Preparation | Finishing | AeroVee | Flight Test | Scratch Building


Finishing:

Simple Small Fairings


Click to Watch Video

 

John Monnett shows how to use common Plumber's Putty to make simple, small fairings.


Polishing Aluminum with Nuvite


Click to Watch Video

 

Kerry Fores of Sonex Aircraft, LLC demonstrates the ins and outs of polishing 6061-T6 aluminum with Nuvite polish. Nuvite polish can be purchased directly from Sonex Aircraft, LLC.


Video Topics:

Tools | Material - Sheet Metal | Material - Extruded Angle | Material - Plate Stock | Material - Titanium | Material - Plexiglass | Drilling & Riveting | Kit Parts Preparation | Finishing | AeroVee | Flight Test | Scratch Building


AeroVee Engine:

For a full list of AeroVee resources, including downloadable manuals & instruction sheets, and the AeroVee Assembly DVD, go to the AeroConversions Manuals and Instructions page.

 


Trimming AeroVee Push Rods


Click to Watch Video

 

Jeremy Monnett discusses the proper techniques for measuring and trimming the steel pushrods when assembling the AeroVee Engine Kit.


AeroVee Valve Adjustment Video


Click to Watch Video

 

This video tip details proper techniques for checking and adjusting the valves on your AeroVee Engine. Note that this process is also detailed, step-by-step, in the AeroVee Assembly Manual provided with your AeroVee Engine Kit.


AeroVee Ignition Timing


Click to Watch Video

 

This video tip describes the technique for synchronizing the timing of the primary and secondary ignition modules on your AeroVee Engine. Note that this process is also detailed, step-by-step, in the AeroVee Assembly Manual provided with your AeroVee Engine Kit.


Video Topics:

Tools | Material - Sheet Metal | Material - Extruded Angle | Material - Plate Stock | Material - Titanium | Material - Plexiglass | Drilling & Riveting | Kit Parts Preparation | Finishing | AeroVee | Flight Test | Scratch Building


Flight Test:

Weight and Balance 7-Part Series


Click to Watch Video
  • Part 1: Arm Measurement
    Sonex Aircraft Chief Flight Instrutor and EAA Flight Advisor and Technical Counselor Joe Norris discusses the datum and locations that require an arm measurement used to establish a weight and balance document.
  • Part 2: Weighing the Airplane
    Joe discusses the process and to put the airplane on scales and obtain the total weight.
  • Part 3: Empty Weight and CG
    Using the arm measurements and weight information to calculate the empty weight and center of gravity location.
  • Part 4: Most Forward Weight and CG
    How to calculate the most forward weight and center of gravity location based upon the previously computed empty weight and center of gravity location.
  • Part 5: Most Aft Weight and CG
    How to calculate the most aft weight and center of gravity location based upon the previously computed empty weight and center of gravity location
  • Part 6: Flight Test Weight and CG
    How to calculate the critical flight test weight and center of gravity location based upon the previously computed empty weight and center of gravity location.
  • Part 7: Creating the Report
    How to put all the weight and balance information together to create a useable weight and balance report that will be given to the FAA and kept in the airplane.

Note: This video series is intended to be a detailed primer on the weight and balance data collection and interpretation process, to be applied to any aircraft. Sonex Aircraft, LLC publishes model-specific information and instructions in our Flight Manuals, which should be used in the Weight and Balance process.

Interested in learning more about the factors and variables affecting empty weight, and weight and balance considerations for Sonex Aircraft? Watch our webinar, "Weight, Balance, Engines and the Reality Check" as a video archive!


Determining VSO Speed


Click to Watch Video

 

Sonex Aircraft Chief Flight Instrutor and EAA Flight Advisor and Technical Counselor Joe Norris discusses Vso speed. This speed is required to be determined for experimental amateur-built aircraft during the phase 1 flight testing process.


Determining Vx and Vy Speeds


Click to Watch Video

 

Sonex Aircraft Chief Flight Instrutor and EAA Flight Advisor and Technical Counselor Joe Norris discusses Vx and Vy speeds. These speeds are required to be determined for experimental amateur-built aircraft during the phase 1 flight testing process.


Video Topics:

Tools | Material - Sheet Metal | Material - Extruded Angle | Material - Plate Stock | Material - Titanium | Material - Plexiglass | Drilling & Riveting | Kit Parts Preparation | Finishing | AeroVee | Flight Test | Scratch Building


Scratch Building:

Making a Sheet Metal Rib From Scratch 6-Part Series

Note: Pre-Formed Ribs and Bulkheads are included in all Sonex Aircraft Kits!


Click to Watch Video

Note: Pre-Formed Ribs and Bulkheads are included in all Sonex Aircraft Kits!


See More at EAA Hints for Homebuilders

 

See many of these videos and more on the EAA's "Hints for Homebuilders" online video series!


 

Click to verify BBB accreditation and to see a BBB
report.

| Home | Choosing Sonex | Company | Kits | Support | Builder Network | Sport Pilot | Ordering | Press Room |

© Copyright Sonex Aircraft, LLC -- All Rights Reserved

Subscribe to Sonex and AeroConversions Mailing Lists and News Feeds