Video Topic Categories:
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Tools:
Sonex Recommended Tool Videos
Sonex, LLC now has a 3-part video series discussing the tools recommended to build a Sonex Aircraft. For a complete listing of tools recommended to build Sonex Aircraft, see the Sonex Required Tools Page.
Cleco 101
Charlie Becker of EAA tells you everything you need to know about Cleco temporary fasteners.
Super Simple Dimple Die
Jeremy Monnett of Sonex Aircraft demonstrates how to dimple sheet aluminum to accept countersunk rivets using Sonex, LLC's Super Simple Dimple Die.
Homemade Dimpling Tool
John Monnett shares how to make a homemade, simple dimpling tool that works great in tight places. Also be sure to check-out the Sonex Super Simple Dimple Die.
Torque Wrench Basics
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.
Material - Sheet Metal:
Cutting with Metal Snips
Although most parts in a Sonex Aircraft kit come pre-cut, using snips to properly cut sheet metal is still an important homebuilding skill that you will need.
This video demonstrates the techniques for cutting out a wing rib blank for those who are scratch-building, but the basic skills apply for all builders. See the whole series, "Making a Sheet Metal Rib from scratch" under the Scratch Building topic area.
Note: Pre-Formed Ribs and Bulkheads are included in Sonex Aircraft Kits!
Using a Fly Cutter to Cut Holes in Sheet Metal
Although most parts in a Sonex Aircraft kit come pre-cut, using a fly cutter is a skill that even full kit builders may need to cut inspection holes, etc.
This video demonstrates the techniques for using a fly cutter to cut a lightening holes in a sheet metal wing rib blank, for those who are scratch building. See the whole series, "Making a Sheet Metal Rib from scratch" under the Scratch Building topic area.
Note: Pre-Formed Ribs and Bulkheads are included in Sonex Aircraft Kits!
Material - Extruded Angle:
Cutting Aluminum Using a Bandsaw
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
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.
Aluminum Angle Adjustment
EAA Flight Advisor and Technical Counselor Joe Norris demonstrates how to make small adjustments to change the 90 degree angle in 6061-T6 aluminum angle.
Closing Aluminum Angle
This video tip features Sonex, LLC employee Kerry Fores demonstrating techniques for reducing the angle of 90 degree extruded aluminum angle stock.
Bending Aluminum Angle with a Wrench
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.
Material - Plate Stock:
Bending Aluminum Plate with an Arbor Press
This video tip features Sonex, LLC employee Kerry Fores demonstrating the technique for using an arbor press to bend thick sheet metal.
Material - Titanium:
Drilling Titanium Gear Legs
This video tip features Sonex, LLC employee Kerry Fores demonstrating techniques for drilling Sonex Aircraft Titanium Gear Legs.
Material - Plexiglass:
Drilling Holes in Plexiglas
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.
Drilling Holes in Plexiglas Using a Unibit (Step Drill)
EAA Technical Counselor Joe Norris demonstrates how to drill holes in acrylic parts such as a canopy using a unibit step drill.
Yes, We Sent You the Right Canopy!
Occasionally we get emails and calls from customers saying that we sent them the wrong canopy. Not so, although it may look deceiving. Notice the writing along the long edges of the canopy that says "Front". Align the area marked front with the nose of the aircraft and drape the canopy over the sides.
Cutting and Fitting a Sonex Aircraft Canopy
In this segment, John Monnett, founder of Sonex, 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 & Riveting:
Solid Riveting Sonex Aircraft Main Spars with a Bolt and Hammer
Joe Norris demonstrates the "Bolt and Hammer" method for driving the 5/32" diameter AD solid rivets used in Sonex Aircraft main wing spars. This technique is considered a safer technique for novice builders, and eliminates the need for expensive riveting equipment.
Note: Pre-Assembled Main Wing Spars are available for all Sonex kits, eliminating the need for builders to do any solid riveting!
Drilling Piano Hinges
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 in Tight Places
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.
Pull Riveting in Tight Places
Charlie Becker of EAA describes his special techniques for installing blind rivets in tight places.
Cleco 101
Charlie Becker of EAA tells you everything you need to know about Cleco temporary fasteners.
Drilling Titanium Gear Legs
This video tip features Sonex, LLC employee Kerry Fores demonstrating techniques for drilling Sonex Aircraft Titanium Gear Legs.
Drilling-Out a Rivet (Blind Rivets Demonstrated)
Joe Norris of EAA demonstrates the proper technique for drilling-out blind rivets.
Drilling-Out a Driven Rivet
Jack Dueck of the EAA Homebuilders' Council demonstrates the proper techniques for drilling-out solid driven rivets.
Kit Parts Preparation:
Blue Lining a Rib for Installation
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.
Removing Powder Coating
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
This video tip discusses preparation of Sonex Aircraft Rotationally Molded Cross-Linked Polyethylene 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.
Note: Sonex Oops Fittings are standard installation on all current Sonex Aircraft Fuel Tanks -- molded-in fittings are no-longer provided with tanks.
Finishing:
Simple Small Fairings
John Monnett shows how to use common Plumber's Putty to make simple, small fairings.
Polishing Aluminum with Nuvite
Kerry Fores of Sonex, LLC demonstrates the ins and outs of polishing 6061-T6 aluminum with Nuvite polish. Nuvite polish can be purchased directly from Sonex, LLC.
AeroVee Engine:
For a full list of AeroVee resources, including downloadable manuals & instruction sheets, and the AeroVee Assembly DVD, go to the AeroConversions Manuals and Instructions page.
Trimming AeroVee Push Rods
Jeremy Monnett discusses the proper techniques for measuring and trimming the steel pushrods when assembling the AeroVee Engine Kit.
AeroVee Valve Adjustment Video
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.
AeroVee Ignition Timing
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.
Flight Test:
Webinar - First Flight in Your Homebuilt
EAA Flight Advisor and Technical Counselor Joe Norris walks you through the most important step in the building process.
Weight and Balance 7-Part Series
Part 1: Arm Measurement
EAA Flight Advisor and Technical Counselor Joe Norris discusses the datum and locations that require an arm measurement used to establish a weight and balance document.- Part 2: Weighing the Airplane Joe discusses the process and to put the airplane on scales and obtain the total weight.
- Part 3: Empty Weight and CG Using the arm measurements and weight information to calculate the empty weight and center of gravity location.
- Part 4: Most Forward Weight and CG How to calculate the most forward weight and center of gravity location based upon the previously computed empty weight and center of gravity location.
- Part 5: Most Aft Weight and CG How to calculate the most aft weight and center of gravity location based upon the previously computed empty weight and center of gravity location
- Part 6: Flight Test Weight and CG How to calculate the critical flight test weight and center of gravity location based upon the previously computed empty weight and center of gravity location.
- Part 7: Creating the Report How to put all the weight and balance information together to create a useable weight and balance report that will be given to the FAA and kept in the airplane.
Using GPS to Verify Airspeed
An easy way to verify the accuracy of your airspeed indicator is by using GPS ground speed data. EAA Flight Advisor and Technical Counselor Joe Norris gives tips to accomplish this essential task for all flight test programs.
Determining VSO Speed
An easy way to verify the accuracy of your airspeed indicator is by using GPS ground speed data. EAA Flight Advisor and Technical Counselor Joe Norris gives tips to accomplish this essential task for all flight test programs.
Determining Vx and Vy Speeds
EAA Flight Advisor and Technical Counselor Joe Norris discusses Vx and Vy speeds. These speeds are required to be determined for experimental amateur-built aircraft during the phase 1 flight testing process.
Trim for Hands Free Flight
Many airplanes require some form of a fixed trim tab to achieve that desirable "hands-free" flight condition. EAA Flight Advisor and Technical Counselor Joe Norris Joe Norris gives some suggestions for simple but effective fixed trim devices.
Scratch Building:
Making a Sheet Metal Rib From Scratch 6-Part Series
Note: Pre-Formed Ribs and Bulkheads are included in all Sonex Aircraft Kits!
Part 1: Lay-Out of Rib Blanks
Kerry Fores of Sonex Aircraft walks you through how to lay out your blank using the "magic washer" trick.- Part 2: Cutting-Out Rib Blanks Kerry Fores walks you through how to cut out your blank using the Malco snips.
- Part 3: Fly-Cutting Lightening Holes Kerry Fores demonstrates how to use a fly cutter to make lightening holes.
- Part 4: Forming Rib Flanges Kerry Fores illustrates how to form the flanges of a rib using Sonex Form Blocks.
- Part 5: Flanging Lightening Holes Kerry Fores illustrates how to flange lightening holes using Sonex Flanging Dies.
- Part 6: Fluting Rib Flanges Kerry Fores shows you how fluting the rib flanges will straighten out a rib.
- Blue Lining a Rib for Installation The use of a "blue line"o; mark makes installation of a sheet metal rib very easy. In this video, Kerry Fores shows you this handy technique.
Note: Pre-Formed Ribs and Bulkheads are included in all Sonex Aircraft Kits!
See More at EAA Hints for Homebuilders
See many of these videos and more on the EAA's "Hints for Homebuilders" online video series!
Kitplanes Magazine Metal Magic Series
We also recommend checking-out the Kitplanes Magazine Metal Magic online video series featuring SubSonex and Xenos builder Paul Dye.
