Sonex Highwing Update: Tail Load Test, Tail Kit Production, Wing Tip Testing, and More!

The Sonex Highwing horizontal tail static load test was conducted in-accordance with established FAA and ASTM standards on October 23rd. Weights were applied to the tail simulating spanwise lift distrubtion across the surfaces in progressively increasing load cases including limit loads (+6G for aerobatic gross weight, +4.4G for max gross weight), structural ultimate loads (limit loads multiplied by a standard safety factor), and beyond. Specific to ASTM testing standards, an asymmetric load was also applied at ultimate with 100% of the load on the right-hand sabilizer and 65% of the load on the left-hand stabilizer to test tail’s attachment to the sample fuselage fuselage section built for this test. We also tested the elevator at ultimate load to validate aerobatic “check maneuver” loads.

Consistent with all Sonex aircraft tail structures, the Highwing tail performed well in-excess of the required loading and was tested to 150% of ultimate load (225% of design limit load) with no failure (breakage) or yielding (permanent deformation) of the structure or sample fuselage section. This feature of Sonex designs not only ensure structural capability of the tail in all flight regimes, but also eliminates concerns with moving the aircraft around by the tail in your hangar.

Sonex Highwing horizontal tail test article with sample fuselage section for asymmetrical testing.

The Sonex steel I-beam test fixture had to be reinforced with additional steel angles for asymmetrical testing.

 

 

The Highwing horizontal tail survived 150% of ultimate load with no failure (breakage) or yielding (permanent deformation).

A happy load test crew! Left to Right: Tony Jones, Tom Turner, Mark Schaible, Cris Nash, Char Schaible, Tyler Nash.

The Highwing tail deflected over 2 inches during the test but returned to its original deflection with no signs of permanent deformation.

Thanks to Casey Cooper, perched atop a ladder to help us document the Highwing tail load test during his visit to Oshkosh.

Sonex Highwing with test set of full span wing tips installed.

We were very fortunate to have Sonex builder and owner of Cooper Aircraft Corporation, Casey Cooper visit us for two days last week. Casey witnessed our tail load test on Thursday and helped with some of the video documentation for the test, and worked with our team on preliminary planning for the installation of the Rotax 915iS in the Tricycle Gear Highwing prototype.

On Friday, we also invited Casey to fly the Highwing with Sonex test pilot Joe Norris to give us his feedback. Casey’s feedback was quite positive and informative as an outside source with extensive experience regularly flying his Sonex along with a multitude of other homebuilt and Light Sport aircraft for his family’s maintenance and training operation. See his thoughts on the Highwing in his Instagram post on this page.

Preliminary fitting of the Rotax 915iS on Sonex production manager Cris Nash’s project aircraft in-preparation for the engine’s installation on the Tricycle Gear Sonex Highwing prototype. Sonex and Cooper Aircraft Corporation are collaborating on a dedicated cowling design for the installation to attractively cowl the engine and allowing maximum performance with minimum cooling drag.

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Sonex Highwing Kit Pricing:

While total kit price has not changed, we have redistributed some of the Sub-Kit items to better match the arrangement of our existing Sub-Kits, including separate sale of the engine mount and cowling. See our updated kit prices below and on the Sonex Web Store.

Complete Kits:

• Complete Airframe Kit: $39,000
• Quick Build Kit: $55,000
• Tri-Gear Option for Complete Airframe Kit or Quick Build Kit: $1,250

Sub-Kit Pricing:

• Tail Kit: $2,250
• Fuselage Kit: $14,450
• Fuselage Quick Build Upgrade: $10,000
• Wing Kit: $12,950
• Wing Quick Build option not available separate from fuselage purchase
• Gear & Controls Kit: $5,600
• Tri-Gear Option for Gear & Controls Kit: $1,250
• Engine Mount & Cowling (Std Gear): $3,750
• Engine Mount & Cowling (Tri-Gear): $3,350
• Kit Minus Tail Package: $36,750

 

 

Buy Your Highwing Today!

Kit Reservation Deposit: $500 Tail Kits Available for $2,250 Complete Airframe Kit: $39,000 (base price) Highwing Quick Build Kit: $55,000 (base price) Highwing Kits: See All Pricing and Order Now!   Highwing PDF Order Form The Bottom Line: What Will My Highwing Cost? Shipments Begin Year-End 2025! Kit Reservation Deposits are refundable less a $50 cancellation fee. Deposits for Complete Airframe Kits, Quick Build Kits and Sub-Kits are non-refundable. See Sonex Terms & Conditions for details.

See Previous Sonex Highwing Updates!