https://players.brightcove.net/627008079/7MKHE9SrL_default/index.html?videoId=1432781652
From:
2 Likes
I was able to get my hand riveter in there. Get the RV-12 angle rivet tool if you dont have one as well as an angle drill. You can just unbolt the bracket below it as well.
2 Likes
My hand riveter is too big to fit in there. 
I’ll just pull the fitting. I have the rv12 corner tool in the mail. So far I’ve been using a 12” bit for tight drilling, works really well. Thanks guys!
We had discussion on the old forum and pictures. I’ll take and post pictures of my rivet stuff after Oshkosh.
2 Likes
Rudder drive assembly done! Next is cutting the rudder blank. Complex shape. I’m going to lay it out and take a break then come back with fresh eyes and see if I did it right.
by the way, the hstab assembly took 17.5 hours all in.
3 Likes
After a week out of town I started work again and laid out the rudder skin cut. I’m not very happy with it. The left side is pretty good but I feel the extended cutout on the right side is too long. Does this look correct to y’all?
left side:
Right side
Sammy, are you using the revisions for that plan? Drawing Revisions – Sonex Aircraft There was a revision made on that cutout, it was marked on the plans about 1/4" too long. Now yours matches mine. Since I was the first customer to build the rudder I found the discrepancy and sent it in so others hopefully wouldnt have this issue. It’s only an aesthetic issue. SHX-V05_Rev_A.jpg (518×317)
4 Likes
Thanks Chris, I didn’t know about those revisions! Lucky for me my plans are hot off the press and the revisions are in there. It looks like the change is to the left side where my right side looks funny.
I will cut the slot short and fit the part. I can open it up more if I’m missing something.
This is from Chris’s build log:
Nice and tight. I must be measuring it wrong. I put one leg of my square along the right skin and hit the LE with the other leg. Maybe the one leg should be parallel with the table and the other should hit the LE.
This dimension is difficult for me to understand. Is it the distance to the end of the notch in the plane of the lower skin?
That’s how I interpret it. You can cheat and slide the bottom rib in to mark it.
3 Likes
Ok. I misinterpreted it. Yes, I think I will cheat with the rib. I’ll make the big cut first, fit the rib and cut the notches. Nice to mess up the layout and figure it out before cutting! Also the elevators are short enough to mess up a rudder cut and turn it into and elevator skin, which is why I planned two cuts.
1 Like
Just fit the rib and mark it. I think i mentioned in my builders log that had I done that I would have saw and saved myself from making the mistake of cutting it to the plans with too long a notch. Sorry, I did realize you were talking about the opposite side I was.
I messed up the rudder hinge and made it an elevator hinge. Saved me from having to buy a new hinge. Yup, build the rudder before elevators!
2 Likes
Thanks Chris! Your build log is a great resource, thank you VERY MUCH for that!
1 Like
Also make sure you check the drawing updates on the Sonex Webpage. A new one for the HW/Pheonix came out today (7/31/26).
2 Likes
I got the email. New HW builders should subscribe, there are typically a bunch of SBs and revisions for new designs from Sonex.
1 Like
Clean it up with a file. If you have edge distance it’s fine. Loss of style points though.
1 Like
Any tips to improve technique? I tried to get the inside corner radii by drilling a hole but then I didn’t hit it right with the snips.
I used a standard compound snip, do the long ones work better?