I doubt it’s stocked anywhere with the folds in the right places. You’d likely need to buy a sheet, cut it, and bend it yourself. I usually buy my raw material from Metal Supermarkets. Depending on the location (here in the Baltimore area, for example), they could do the folds along the length when you buy the material. Then you would trim and form the smaller folds at the ends. At least, that’s how I would do it.
2 Likes
You need a sheetmetal brake. The purpose of the hobby is to buy tools!
4 Likes
Thanks for the ideas…
I have been doing more digging since the post of trying to rebuild the part. HomeBuiltHELP has the videos on scratch building airplanes as most probably have heard or watched.
https://youtu.be/rvKUrnd1bbE?si=gtXMoWjonQvtNrTE
At the end of this vid on YT they talk about plans that callout the “developed length” of parts for scratch bending. In the example I believe it is a Zenith horiz stab spar. Not yet sure how to reverse engineer that dimension of the part I want to build. Perhaps trial and error until the part matches. Fairly sure the bends are all 1/8” radius if that is the correct way to designate the bend. Seems like that is just about the smallest bend that 6160-T6 .032 can accommodate without cracking. There is a advisory circular with the bend specs for different aluminum alloys. The developed length includes the part side dimensions and the bends.
I have the intent now to get some flat stock of 6160-T6 and see what I can learn.
HomeBuiltHelp also as plans online for a metal break. I just put together a welding table so will look into those plans more for the metal break. A few guys have vid series detailing those plans. It is always fun to weld stuff.
The Cotton rule of tool acquisition lives on!
1 Like
Here is a link to an early Sonex plans builder’s homemade brake.
Ref.: Dave’s Sheet Metal Bending Brake.
Wes
2 Likes
Research ….
I did a “scratch build” search here at SonexPilots.org and have lots of posts to go through. Saw a Bryan Cotton post from back a fair bit that has as a rule of thumb that bend radius should be 4 times the metal thickness. For .032 that is pretty much 1/8” .
Would be interesting to find someone with scratch build plans on a Sonex B and see if there is a callout for the develop length on the rear spar of the horizontal stab. I have looked at build logs of Sonex B models and the tail design appears to be very similar to the High Wing tail.
More to learn!
2 Likes
As far as I know, there aren’t any scratch build plans for the B model - only for the legacy/A model. But the stabilizers are probably really close (if not identical) between the legacy and B-model. I believe the only thing they changed between the A and the B was forward of the tail cone box. In fact, there’s an A-to-B upgrade kit that (I believe) leaves the empenage alone.
2 Likes
For Developed Length look at this video https://www.youtube.com/watch?v=h9fxo95D4Ik
1 Like
Question for anyone….
I’ve seen “for sale” claimed complete kits of Sonex B or Waiex B and am considering going that route.
It is anyone’s guess of whether the High Wing will make a come back anytime soon.
I am new to the “complete” kit buy idea in after market. With a Vans or Rans there are parts availability. Some of the Sonex models have the Jabiru engine mounts yet no cowling. Figuring out what is missing and could be found in the wild is the trick perhaps.
Am I realistically thinking of difficulty going this route? Would the risk be stranded dollars and not able to find all needed parts? Perhaps I should only look for kits that have continued production.
Thanks
I’d do it. But I think the answer if it’s a good idea or not is highly dependent on the person. Same as building a kit with factory support, but a little harder maybe.
1 Like
I bought my kit second-hand and it was a good choice for me. Saved me several thousand dollars and the guy threw in basically all of the tools he’d bought because he no longer wanted to build and he had no use for them anymore.
A couple things to consider:
-
why is the seller interested in selling? Just lost interest? Concerned about lack of support? Moving? There’s lots of reasons, and a few of them would be red flags.
-
if the seller has started on it (which is almost definitely the case), does the workmanship align with the standards you’d want for your airplane? You’ll want to do a pre-buy and look closely. And let them know beforehand that you won’t be buying it that day - you’ll want to look at it, take some pictures, and think about it a couple of days (meanwhile post a few pics here so we can all comment on the build quality).
-
this forum can give advice, but not factory support. Since there is no longer factory support available (for now, anyway) you’ll really be in your own. Not a deal breaker, but something to consider. Honestly, my favorite build sessions have been when I’ve scratch-built something. It’s very rewarding to see some piece of aluminum stock or sheet become and airplane part.
-
one thing I might be concerned about is the ability to register it as a second-hand kit. When I bought mine, I had to pay Sonex a $100 fee to transfer the paperwork from the previous owner to me. The FAA needs to have a full chain of ownership from the factory to you. I’m sure it’s not insurmountable, but I recommend calling your local FSDO to ask before dropping tens of thousands of dollars for what may end up being a static display.
If anyone else has thoughts/experience on that last point, I’d be very interested in knowing. Please comment. I’m nowhere near registering my kit yet, but I’m a little nervous about what bureaucratic nonsense might ensue when the time comes over the Sonex closure.
2 Likes
I purchased the whole kit and caboodle from the estate of the original builder. Provenance is critical. I purchased my Sonex from an estate. When I registered as owner of plans SNX-0414 Sonex required the BOS signed by the Executor of the Estate along with a copy of the document appointing them as Executor. Sonex then issued a new Bill of Sale directly from Sonex to me for plans SNX-0414.
So, imo, Every registered owner of a set of plans will have a BOS from Sonex… somewhere.
If buying from an estate, make sure you can document a continuous chain of ownership.
Due to chain of ownership concerns, I would be extremely hesitant to purchase a kit from a plans holder who is not a registered owner unless they provide those documents at the presale inspection.
With respect to Sonex support, try your local EAA chapter’s technical counselors. They are great.
The Cleanex I’m building has a nose bowl, and cowling adapted from a Zenith 601, and a prop spinner from Van’s.
We are going to have to get creative.
2 Likes
Others have some very good advice. One thing I will add - and this has already been mentioned - have a critical eye for the builder’s craftsmanship and attention to detail. If you see things that don’t look great, then you have to start looking deeper. It is possible that there are deeper problems that are not immediately visible. Look at simple things like cotter pins, bolt lengths, rivet heads that might not be flat, etc. Things that might indicate a pattern of the builder’s workmanship.
2 Likes
Thanks all for the input!
I sold a RV7 kit and did give the buyer a BOS ….I talked to Vans and it seemed like a non issue to them.
Our EAA chapter seems to be more into airport breakfast and flying kids verses any airplane building. Those are not bad things just lacking in technical skill.
The kit at the top of my list is an estate sale. The guy selling the kit for the family is Pete Krotje who is the original founder of Arion Aircraft. He might be able to judge quality build more than some. At least I had that common ground with him after having just attended the Jabiru class at Arion.
I would have to fly commercial and rent a Uhaul to inspect and pick up the kit. There would be the added pressure of having done all that then not buying the kit. I did that sort of once already. Drove a Uhaul eight hours to Reno thinking I was going to buy a Zenith 701 and went back home empty.
I will see how this goes. One mentor says don’t search for something more than 500 miles away. Seems like every time I get serious about going all in then something happens. 
It’s a Waiex, important to make sure you are cool enough first!
2 Likes
When I went to inspect the project, I brought some cash for a deposit. Enough so they know I’m serious, but not so much that I couldn’t walk away from it.
The project’s location was about a 3 hour drive. easy to do in a day.
I was due for a good challenge.
2 Likes
…. Does flying a Waiex then add to the coolness factor?
2 Likes
Yes, but those points can’t be applied to meeting prerequisite requirements.
Wes
4 Likes
Updates —
I looked back at the posts on my HW project. From the high of getting the tail kit to the low of thinking it would become hanger art on the wall. Then back to a new start. Quite the range of emotion or at least highs and lows.
The tail is on the way to getting put together… horiz stab spar parts and elevator horns now here. Part cleanup, Cleco, Drill, Take apart, Deburr, Cleco, Rivet — The Mantra
Got the phone call from “Ozzy” (Stephen Osborne) about getting on with the HW ordering. It was good to get the actual phone call. I had sent some SMS to the Sonex phone number and had finally got answers back. Now have placed the complete order for the whole HW kit, taking advantage of the new 30% deposit option. Sent a check in slow mail. It cleared the bank so will see if the fuselage pile shows up down the road. There was some thought that the wings would make it out to production first. Now it seems like it will be the fuselage. We will see…
2 Likes
I heard today its back to fuselage being next in production as well, instead of wings first that the most recent video updates said.
1 Like
Yeah, Mark said that it would have to be fuselage first when I visited the factory early this year.
I saw the video as well & was hoping that they figured out doing the wings first - finding space to store finished wings is much easier than a finished fuselage.
1 Like