Trimming AeroVee Push Rods

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

Bending Aluminum Plate with an Arbor Press

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

Removing Powder Coating

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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

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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.

Closing Aluminum Angle

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

AeroVee Ignition Timing

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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.

Drilling Titanium Gear Legs

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

Polishing Aluminum with Nuvite

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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.

AeroVee Valve Adjustment Video

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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.

Cutting and Fitting a Sonex Aircraft Canopy

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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.

Drilling Holes in Plexiglas

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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.

Making a Sheet Metal Rib From Scratch (part 1 of 6)

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Making a Sheet Metal Rib from scratch (part 1 of 6). Kerry Fores of Sonex Aircraft walks you through how to lay out your blank using the "magic washer" trick.

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

Making a Sheet Metal Rib From Scratch (part 2 of 6)

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Making a Sheet Metal Rib from scratch (part 2 of 6). Kerry Fores walks you through how to cut out your blank using the Malco snips.

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

Making a Sheet Metal Rib From Scratch (part 3 of 6)

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Making a Sheet Metal Rib from scratch (part 3 of 6). Kerry Fores demonstrates how to use a fly cutter to make lightening holes.

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

Making a Sheet Metal Rib From Scratch (part 4 of 6)

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Making a Sheet Metal Rib from scratch (part 4 of 6). Kerry Fores illustrates how to form the flanges of a rib using Sonex Form Blocks.

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

Making a Sheet Metal Rib From Scratch (part 5 of 6)

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Making a Sheet Metal Rib from scratch (part 5 of 6). Kerry Fores illustrates how to flange lightening holes using Sonex Flanging Dies.

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

Making a Sheet Metal Rib From Scratch (part 6 of 6)

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Making a Sheet Metal Rib from scratch (part 6 of 6). Kerry Fores shows you how fluting the rib flanges will straighten out a rib.

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

Blue Lining a Rib for Installation

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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.

Bending Aluminum Angle with a Wrench

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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.

Cutting Aluminum Using a Bandsaw

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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

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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.

Super Simple Dimple Die

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

Torque Wrench Basics

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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.

Drilling Piano Hinges

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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-Out a Rivet (Blind Rivets Demonstrated)

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

Drilling-Out a Driven Rivet

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

Cleco 101

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

Pull Riveting in Tight Places

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

Drilling in Tight Places

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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.