Instruction Sheets

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Instruction Sheet Topic Categories:

• Finishing
• Firewall Forward
• Fuselage Construction
• General Information
• Inspection (SubSonex)
• Instruments
• Landing Gear
• Tail Construction
• Wing Construction

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Finishing

Nuvite Polishing Instructions
(Updated 04/23/12)

Multi-page instructions detailing how to achieve that perfect shine using Nuvite products.

Also be-sure to see our Nuvite Polishing Tips video on the Sonex Video Tips page.

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Firewall Forward

AeroConversions Air Filter Assembly Installation
(Updated 05/31/06)

Details installation of the AeroConversions Air Filter Assembly.

 

AeroConversions CHT Probe Installation
(Updated 03/19/13)

Installation instructions for AeroConversions CHT Probes.

 

AeroConversions Oil Separator Installation
(Updated 03/26/13)

Installation instructions for AeroConversions Oil Separator.

 

AeroVee 2-into-1 Stainless Exhaust Installation
(Updated 05/21/08)

Installation instructions for the AeroConversions AeroVee 2-into-1 Stainless Exhaust.

 

AeroVee Break-In Procedures
(Updated 11/11/09)

Break-In procedures for the AeroConversions AeroVee Engine Kit.

 

Cowling Installation Instructions
(Updated 08/22/08)

Supplemental documentation regarding fitting and installation of Sonex Aircraft fiberglass cowlings.

 

Jabiru 3300 Oil Cooler Upgrade Installation Instructions
(Updated 08/11/08)

Installation instructions for the Sonex/Jabiru Baffle Kit Oil Cooler Upgrade, designed to accommodate use of the Aero-Classics oil cooler, which is more compatible with current Jabiru 3300 exhaust system installations. Note: AeroConversions Jabiru Universal Baffle Kits include materials and installation instructions to accommodate the Aero-Classics oil cooler.

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Fuselage Construction

Canopy Installation Tips
(Updated 02/02/06)

This PDF file is a duplicate of the sticker that ships adhered to your canopy.

 

SNX-G02 Fuel Tank Fittings Installation
(Updated 06/09/23)

Beginning October, 2015 Sonex Aircraft Fuel Tanks are no longer supplied with molded-in fittings, and Sonex Aircraft Oops Fittings must be installed by the builder. This drawing details Oops Fitting installation locations and procedure, and is included with your fuel tank. This document does not eliminate the need to read and follow Fuel Tank Installation Tips instruction sheet, found below.

 

Fuel Tank Installation Tips
(Updated 03/16/10)

Installation instructions for the rotationally molded fuel tank.

 

Oops Fittings Installation Instructions
(Updated 11/17/22)

Installation instructions for fuel tank Oops Fittings.

 

Upholstery Installation Instructions
(Updated 06/16/10)

Installation instructions for Sonex Aircraft Upholstery Packages.

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General Information

Using the Sonex Drawings
(Updated 2009)

Basic description of the Sonex drawing system and how it functions.

 

Kit Components Notice
(Updated 06/25/13)

Advisory Letter included with all new Complete Airframe Kit and Sub-Kit packing lists detailing the importance of the packing list throughout the project in identifying parts shown in the plans that are provided with the kit.

 

Gross Weight Advisory Letter
(Updated 01/16/13)

Advisory Letter regarding the negative LSA Compliance and Safety implications of certifying and/or operating a Sonex Aircraft in excess of the aircraft's published design maximum weight.

 

Bending Flat Parts
(Updated 01/26/09)

Some airframe parts require bending, whether bending a flat part to a given angle, or reforming an existing angle (rib flange, channel flange, etc.) to a proper fit. This can easily be accomplished using simple tools and the techniques illustrated in this instruction sheet.

 

Laser Flash Explanation
(Updated 02/02/06)

Descriptions of typical laser assist gas "flash" residue and instructions for deburring laser-cut parts.

 

Reforming Aluminum Extrusions
(Updated 01/20/09)

Some airframe parts require that the 90-degree aluminum extrusion from which they are made be reformed to a greater, or lesser bend angle. This is easily accomplished with common tools using the techniques illustrated in this instruction sheet.

 

Sonex Material Planning Guide (for Scratch Building)
(Updated 09/2000)

This material planning guide is provided to help Sonex scratch builders purchase and optimize raw materials in the most efficent sizes and quantities to minimize waste.

 

Sonex Aircraft Fly-In Traffic Instructions
(Updated 05/31/06)

Fly-In traffic instructions (1.4mb PDF File) for all pilots flying in to any Sonex event, including events during EAA AirVenture Oshkosh. Please note that if you are flying-in during AirVenture, you must also download and study the AirVenture NOTAM from EAA as well.

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Inspection (SubSonex)

SubSonex Inspection Program (Fillable PDF)
(Revision B Updated 10/10/24)

Download Fillable PDF Form for filing with the cognizant Federal Aviation Administration (FAA) FAA Flight Standards District Office (FSDO) - Required for all turbine powered experimental aircraft.

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Instruments

Electric Instrument Installation Instructions
(Updated 10/27/08)

Generic Letter with Sonex-Specific recommendations to set up many different makes and models of Electronic Cockpit Instrumentation for Monitoring Flight and Engine Data.

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Landing Gear

Wheel and Brake Assembly and Installation Instructions
(Updated 06/16/06)

Two page instruction sheet instructing how to prepare Azusa Wheels and Brakes for installation. Information supplements drawing SNX-L01.

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Tail Construction

Sonex Tail Spar Instructions
(Updated 02/02/06)

Instructions for final preparation and assembly of pre-fabricated Sonex Horizontal Tail Spars.

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Wing Construction

Wing Rib Forming Instructions (Scratch Building)
(Updated 05/09/13)

Instructions for forming Wing Ribs (only needed by Scratch Builders as pre-formed wing ribs are included with all Complete Airframe Kits and Sub-Kits).

 

Gusset Stock Instructions
(Updated 03/30/06)

Instructions for use with laser-cut blanks for SNX-W15-08/09, SNX-W16-07, and SNX-W16-08.

 

Sonex and Waiex LH Main Wing Spar Exploded View Supplement
(Updated 06/29/06)

Sonex and Waiex RH Main Wing Spar Exploded View Supplement
(Updated 06/14/06)

Supplemental exploded view of main wing spar assemblies for the Sonex and Waiex. Supplement to drawings SNX-W08 and/or WIX-W14.

 

Spar Cap Instructions
(Updated 06/21/06)

Instructions for final preparation of machined Spar Caps.

 

Spar Spacer Instructions
(Updated 02/02/06)

Instructions for use of Spacer Tools in construction of main wing spar.

 

Wing Installation/Removal Instructions
(Updated 03/27/06)

12 page instruction sheet on installing/removing Sonex/Waiex wings.

 

Wing Squaring/Skinning Instructions
(Updated 05/18/06)

Due to popular demand, we have published SNX-W07-02, an instruction sheet detailing a suggested method for squaring and skinning your Sonex, Waiex or Xenos wings.

 

Wing Tip Installation
(Updated 11/10/06)

Instructions for installation of fiberglass wing tips on the Sonex and Waiex.

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