Project: Jill's_WaiexB   -  
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Builder Name:Juan Canton   -  
Project:   Sonex - Waiex-B   -   VIEW REPORTS
Total Hours:447.8
Total Flight Time:
Total Expense:$60367.98
Start/Last Date:Aug 30, 2019 - No Finish Date
Panel:Garmin G3X + GNX375
 
Friendly URL: https://eaabuilderslog.org?s=Jill's_WaiexB

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Apr 02, 2024     Payment for Engine Mount Modificaiton - (.1 hour)       Category: Firewall Forward
Partial payment sent for parts for engine mount modification.

FWF remaining cost 3200.00


 
Apr 02, 2024     Paid for Propeller Kit from Sensenich via Azalea Aviation - (.1 hour)       Category: Propeller
Cost of propeller paid in full.


 
Mar 30, 2024     Right Flap Final Assembly - (3.8 hours)       Category: Wings
Up drilled all holes on the right flap to final size, then disassembled and deburred all parts and finally reassembled and final riveted right flap.


 
Mar 21, 2024     Cost to ship engine mount for modification - (1.1 hours) Category: Firewall Forward
Created box and shipped engine mount to azalea aviation for modification.
 
Mar 21, 2024     Initial Deposit On Spyder Corvair Conversion Kit - (.1 hour)       Category: Engine
Ordered a Spyder 120 HP Corvair Conversion Engine Kit, Including FWF Kit and Sensenich 3 blade prop kit. Initial Deposit was made today of 40%

7500 Deposit

Engine is 12900.00 - 1000.00 = 11900 for giving 40% down for full Prop/FWF/Engine Package.
Propeller is 3200.00
FWF 3500.00
Total Cost all Three - 18,600.00 with Discount Note Payment for sub components of kits will be marked in their own entries as payments are made.

Engine Kit Cost Remaining 4400.00


 
Feb 24, 2024     Flap Drive Rib - (2.5 hours)       Category: Wings
Worked on the replacement Flap Drive Rib, it was a short day because i needed to order a 120 degree countersink and microstop for some flush rivets.


 
Feb 24, 2024     Microstop and 120 Degree Countersinks - (.2 hour)       Category: Tools
Ordered a set of countersink's and a micro stop so that i could countersink some plates on the flap drve horns since my counter sink bit was 100 degrees and pop rivets are 120 degree's


 
Feb 13, 2024     Replacement Flap Parts - (.1 hour)       Category: Wings
Need to add shipping,

Due to a building error with the flap drive horns where a nut plate should have been drilled with a snug fit i ordered new flap drive plates and flap rib in addition to the necessary rivets for those drive plates.


 
Feb 03, 2024     Right Wing Final Deburring and Riveting - (7.9 hours)       Category: Wings
Finished Deburring the lower wing skin, assembled the wing with all skins and installed the pitot tube after riveting the flush rivets under the pitot mount, then installed the wing tip and riveted all skins.


 
Jan 27, 2024     Right Wing Deburring Pt.2 and Leading Edge Prep - (8.7 hours)       Category: Wings
Removed Pitot Tube for rivet prep, Deburred the Lower Leading Edge Ribs, and the Leading Edge Skin, Then Dimpled Both, After That deburred the lower aft ribs and the Aft Wing Skin, Finally reinstalled the aft Skin and half of the leading edge skin in prep for Riveting.


 
Oct 28, 2023     Pitot Tube Installation Part 2 - (2.0 hours)       Category: Avionics
Finished fabricating and then installing the GAP-26 mount into the right wing. I had to order some tools to flare the Pitot tube ends for the fittings i will be using but otherwise it was a fairly easy correction after addressing the clearance issues encountered the last time.


 
Oct 28, 2023     Flaring Tool and Tubing Bender - (.25 hour)       Category: Tools
Ordered a flare tool for the Pitot tube fittings for the Gap-26 also ordered a tubing bender i will be able to use both when creating brake lines and/or hard fuel line in the future.


 
Oct 14, 2023     Whole Saw Pilot and Saw Mount. - (.5 hour)       Category: Tools
Had to get another center section for the whole saw i purchased to cut out the inspection panel for the pitot tube, Unfortunately the original one i bought looked like it was mislabeled as being compatible with a 4" hole saw and it was not.

Original was 3/8th but this only fits up to 1 1/4 sized hole saws, even though it was labeled up to 6", The 1/2" one is the one that fits the larger hole saws.


 
Oct 14, 2023     Pitot Tube Installation - (4.25 hours)       Category: Avionics
Worked on the Pitot Tube mount and inspection plate creation for the Garmin GAP-26. I decided to utilize the original mounting location of the pitot tube per the plans but with the garmin install kit bracket that location on the inspection plate does not work. Since I did not test fit the mount on the inspection plate before doing all the work to install the mount onto the inspection plate i did not realize this until i went to install the inspection plate on the wing. Since it did not fit i will need to rework the inspection plate bracket mount installation, but the installation of the nut plates into the wing and the cutout of the mount inspection hole will not need to be redone.

For anyone doing this in the future do not use the doubler plate as it will not fit the 4" hole called for in the plans or at a minimum modify it, and do not offset the pitot tube in the inspection plate, you will need to center mount it.

4.75 was the cost of the replacement inspection plate, no shipping included since i already had an order they are going to add this to.


 
Oct 10, 2023     Ordered Dual Stick Upgrade kit - (.25 hour)       Category: Controls
Ordered Dual Stick Upgrade Kit, This kit has a couple of nice features beyond just the dual sticks it also comes with a removable Avionics access panel for AP servos and other items.


 
Oct 10, 2023     Ordered Leather Upholstery - (.25 hour)       Category: Interior Finish
Cost of kit was 1940.00 + 62.00 Shipping

Ordered Gray Heated Leather Interior, with black bulkhead panel and Baggage Sling.


 
May 28, 2023     Right Wing Leading Edge & Root Doubler - (8.2 hours)       Category: Wings
Attached the right wing leading edge after marking the centerline of the ribs, then i did the pilot drilling of the ribs to the leading edge, once that was secure, we moved on to finishing the right wing root doubler assemble and that was also completed minus the drilling to the skin.


 
May 20, 2023     Left Wing Final Inspection and Riveting. - (5.5 hours)       Category: Wings
Double checked all my work on the left wing to make sure i didnt forget anything and then spent the next few hours installing approximately 700 rivets. The only items not riveted are the tip rib as i want to paint that item and the root doubler as that does not get riveted until the wings are installed and rigged.


 
May 14, 2023     Step bit - (.5 hour)       Category: Tools
Had to buy a step bit to finish installing the wiring in the wing


 
May 10, 2023     Ratcheting Wire Crimper - (.1 hour)       Category: Tools
Got a pair of ratcheting wire crimpers and a pair of jaws for insulated and heat shrink connectors.


 
May 01, 2023     Electrical Crimper, Connectors, and Misc Hardware       Category: Tools
Ordered a standard electrical crimper, Some sealed butt splices to extend the navigation light cables, and also ordered some misc fasteners to install the nav lights an pitot tube.


 
Apr 17, 2023     Cutoff wheels for dremel Category: Tools
Ordered some extra cutoff wheels for the dremel as i used the last on on the left wing landing light installation.
 
Apr 16, 2023     Hand Rivet Squeezer, Dimple Die Set, and Safety Wire Setup - (.1 hour)       Category: Tools
Ordered a rivet Squeezer for the install of the next landing light so that i dont struggle as much From Brown Tool and then ordered a safety wire kit and some cherry rivets from Aircraft Spruce.


 
Apr 01, 2023     Inventory part 3 - (3.2 hours) Category: Fuselage
Completed final inventory of the remaining kits minus backorder parts as always sonex does an amazing job of packing stuff and I have to rely on human tetris to try and make stuff fit in my garage,

Only one missing part and 2 parts with a slight variation on pn that I am confirming are usable overall for the number of parts an amazing accuracy percentage.
 
Mar 23, 2023     Inventory part 2 - (3.5 hours) Category: Fuselage
Inventoried the last box, still need to inventory the flat pallet but that should be done tomorrow
 
Mar 23, 2023     Transportation and inventory Part1 - (7.0 hours) Category: Fuselage
Rented a truck and picked up the fuselage along with the rest of the kits that we ordered previously.
Completed inventory on 2 of the 3 boxes, still have 1 box and the flat packed pallet to inventory spent 3 hours getting the truck and kits and 4 hours on the inventory and storage of the kit parts
 
Feb 19, 2023     Wingtip Light Mount and control surface hinges - (8.4 hours)       Category: Wings
We started off by attaching and applying fiberglass to the wing tip light mount in addition to some filler to smooth out the mount cut out in prep for gel coat next week and mounting of the light fixture.

We then proceeded to cut out all of the control surface hinges as some of them are needed for finishing off the wings. Once that was done we mounted the hinges we needed to mount and finished updrilling all but 5 holes on the wings those we will updrill once we are ready to mount the wingtip on as the wingtip is underneath and i didnt want to drill them without the wingtip in place.


 
Feb 19, 2023     Tools and Fiberglass Supplies - (2.0 hours)       Category: Tools
Ordered 2 large drill bits one for the wiring conduit, and one for the tie down hole, Also got the Hole Saw i am going to need for the pitot tube installation, I also got a pair of calipers that we have run into the need to have for various measurements. In addition we bought a bunch of suplies to work with fiberglass and to tools to sand so we can refinish the wingtip light mounts.


 
Feb 04, 2023     Left Wing Leading Edge Skin and Root Rib Installation - (9.5 hours)       Category: Wings
We started by attaching the leading edge skin, we then pilot drilled and clecoed all the interior ribs, After that we started to install the root rib, The original plan was to do both leading edge skins on both wings but it turns out from this point forward it makes for sense to finish out this wing before moving to the left wing. At least for all the drilling and dimpling and what not that is still to be done. We did have to remove the mount brackets in order to install the root rib.


 
Jan 29, 2023     Ordered More Clecos and Drill Bits - (.2 hour)       Category: Tools
Ordered Some more tools, 200 Additional 1/8 clecos, ran out due to building both wings at the same time. In addition i picked up some acrylic drill bits and some more number 40 Jobbers as i am getting low on those and tend to go through those alot quicker than the 30s this is probably due to the fact that initial holes tend to get drilled by the 40's and also that they are smaller so more susceptible to overheating.


 
Jan 23, 2023     Wing Wiring Schematic Design - (2.5 hours)       Category: Electrical
Design of Wing Wiring and Connector Distribution


 
Jan 11, 2023     Wing Wiring and Connectors - (.8 hour)       Category: Electrical
Stein Air Cable 73.33 Shipped, Connectors, tubing, and pin kits 165.83 shipped from spruce.


 
Jan 11, 2023     Pitot Tube Installation Kit from Garmin - (.2 hour) Category: Avionics
Gap-26 Installation kit i originally ordered the generic mast but upon additional inspection i decided to order the official garmin kit as it included backing plates and other features that pair up well with the kit in addition to the ability to change the angle if required. 212.32 from stein, 12.00 for hardware from spruce
 
Jan 11, 2023     Ordered Some Electrical Tools - (.5 hour)       Category: Tools
Flush cutters and tubing cutter from stein air was 16.01 shipped Seal-All Crimpers and pin tool 200.01 Shipped


 
Nov 12, 2022     Clecos and Drill Bits For Wings - (.5 hour)       Category: Tools
Was running short on clecos while building out the wing skins so I ordered 200 more 1/8 since those tend to stay on skins until its time to rivet. and 100 more 3/32 since i was running a bit low on those as well and plan to keep some on the skins until its time to up drill them.


 
Nov 12, 2022     Left wing Upper Aft Skin - (8.5 hours)       Category: Wings
Squared the wing ensured no twist i then attached the upper aft skin on the wing sub structure, we got all the ribs lined up with the skin and drilled and clecoed, then proceeded to drill the front edge of the wing skin that goes through the spar cap. Once that was done, we went ahead and drilled the brackets that strengthen the aileron bell crank bracket. After that we up drilled all the rib holes to final size but did not up drill the leading and trailing edge as we will need to overlap the leading-edge skin and control hinges later, so we wanted to keep those holes small for accuracy.


 
Nov 12, 2022     Tools for Wings - (1 hour)       Category: Tools
Purchased a laser level as well as a builders square, wood shims, and some rachet straps. these will be needed to square and skin the wings.


 
Nov 05, 2022     Left Wing Sub Structure Part 3 & Right Spar Pitot Static Inserts - (3.5 hours)       Category: Wings
We completed the left wing substructure assembly and then proceeded to install the pitot tube routing brackets in the right wing. We are now ready to start attaching skins to the wings but will need to pick up a few tools and work on setting up the wing assembly so that it is square and has no twist before we start the skinning process.


 
Nov 05, 2022     Right Angle Drill - (.5 hour)       Category: Tools
Had to buy a right angle drill becasue i built the substructure first before the pitot tube instalation and was not able to rivet the brackets in the tight space.


 
Oct 30, 2022     Ordered Pitot Static Installation Kit - (.2 hour)       Category: Avionics
While ordering the bolts that i needed to replace that were used to install rib 1 on the left spar i decided to also order the Pitot Static Installation kit i was going to need for the Pitot Tube and AOA Sensor for the garmin panel. This includes all the necessary line and fittings to connect the pitot tube and the static lines. I suspect i might also order a Alternate static valve later for the static side but we will see.


 
Oct 29, 2022     Left Wing Sub Structure Part 2 - (6.0 hours)       Category: Wings
Completed deburring and riveting the ribs to the main spar, I had to steal some screws to get the proper fit up on Rib 1 so i ended up ordering some additional hardware from spruce hence the 7 dollar cost which was mostly shipping as the screws were a little over a dollar and shipping was about 6. When it came time to rivet the rear spar i got through ribs 1 and 2 before getting to rib 3. When reviewing the plans there seemed to be a callout discrepancy in the plans as to what size rivets i should be using for the remaining ribs so i went ahead and stopped and sent an email to the factory to confirm. I am pretty sure it should continue to be CCP-41's similar to the other spar but its better to check then be sorry.


 
Oct 24, 2022     Low Profile Riviter - (.3 hour)       Category: Tools
On the Suggestion of other builders i ordered a 400 series pop riveter by USM,

For other builders the usual suggestion is a PRG 410, I think any of the 400 series works my personal preference is the 412 its very similar to the 410 but has replacable nose pieces for different rivet sizes and is the same price they are all roughly about 20 dollars on ebay.


 
Oct 22, 2022     Left Wing Sub Structure Part 1 - (6.0 hours)       Category: Wings
Completed the fabrication of the spar web spacers, then match drilled and up drilled the fwd and aft rib assemblies, completed the night with a test fit of all parts, next build session i will deburr and rivet the test fitted pieces and complete the drilling and assemble of the rear spar.


 
Oct 21, 2022     Ordered Final Kits Canopy - (.1 hour) Category: Canopy
Estimated Canopy Cost (Including Hardware) 1000

Note this cost was subtracted from the Fuselage kit price.
 
Oct 21, 2022     Ordered Final Kits Controls - (.5 hour) Category: Controls
Multiple Entries for Cost Record Keeping.

Since Gear and Controls are combined i did a 50/50 Split

Total for Kit was 5207.00 so split in half = 2603.50
 
Oct 21, 2022     Ordered Final Kits Gear - (.5 hour) Category: Landing Gear
Multiple Entries for Cost Record Keeping.

Since Gear and Controls are combined i did a 50/50 Split

Total for Kit was 5207.00 so split in half = 2603.50
 
Oct 21, 2022     Ordered Final Kits Engine Bay - (.5 hour) Category: Firewall Forward
Engine Bay Component Kits Ordered. Price Breakdown as follows. Note Multiple posts to accurately track expenses.

Engine Mount Tri Gear Jab 1965.00
Cowling 1005.25

Total 2970.25
 
Oct 21, 2022     Ordered Final Kits Fuselage - (.5 hour) Category: Fuselage
Placed the order for the final remaining kits as Sonex was going to increase prices in two weeks. Making multiple entries to track cost all crating and shipping will be under the fuselage kit.

Cost break Down is as follows:

Fuselage 9849.00
Crating 200.00
Shipping 2021.43
Subtracted Estimated Canopy Cost (Including Hardware) 1000
Total 11,070.43
 
Oct 05, 2022     Fixed two bad rivets - (1.7 hours) Category: Wings
Has to drill out and replace two rivets that did not fully seat plus pulled the 6 other rivets that were not pullable previously
 
Oct 01, 2022     Pop Rivet Wedge and Swivel Head Rivet Gun - (1.0 hour) Category: Tools
Rivet Wedge 28.48
Swivel Head Pop Rivet tool 26.92
I was able to pull the close clearance rivets with the new swivel head tool as its a little bit lower profile but i still want the wedge for the next wing sub structure as it was still borderline with this toll
 
Oct 01, 2022     Right Wing Sub-sturcutre - (10.0 hours)       Category: Wings
Almost completed the right wing sub- structure minus 6 rivets that i ordered a rivet wedge tool to try and get to as i cannot pull them in the location next to the spar channel. This was an interesting part of the build where things are finally starting to look like really wings, It tool a little planning to drill both sets of ribs as they shared holes so you really had to go back and forth between them and being selective with which holes your drilled out i tended to drill the outside holes leaving the two center holes for alignment of the other rib in the smaller cleco size and then using smaller clecos with the larger holes to hold the now aligned ribs as a drilled out the already large holes to match on the new parts. This allowed for both ribs to be drilled without compromising alignment.

With the new swivel head rivet puller i was able to get the last 6 rivets but i also noticed i had 3 bad rivets i need to drill and redo when we get back to building. The rivet wedge will also make those hard to reach rivets less dicey as even with the new rivet puller it was still marginal at best for being able to put enough pressue on the rivet head all though they both pulled cleanly.


 
Sep 19, 2022     6061 Sheet Stock Ordering - (.2 hour) Category: Wings
Needed to order some flat sheet stock of 6061 for some of the spacers I need to fabricate for the wings i probably could have grabbed some scrap from a flap or aileron scrap of aluminum but since those are not yet fabricated and the flat stock is not to expensive i went ahead and ordered to 2"/48" sheets that should be more than enough to make the spacers and leaves a little for any other small miscellaneous parts i need to create.

If you order your wing kit before the fuselage you will not get the flat stock you need for these spacers i reached out to the factory and they shipped me a peice of flat stock so make sure if you are working on your wings to reach out for the flat stock before you need it as it will take a week for you to get it via USPS
 
Sep 18, 2022     Created spacers for wing substructure assembly - (1.0 hour)       Category: Wings
Created some spacers after building my band saw but was unable to create all of them as I was missing some material the 03 call out as shown in the pictures I can probably grab some left over sheet from scrap to make these but I would expect the plans to call that out.


 
Sep 18, 2022     Bandsaw for the workshop - (3.8 hours)       Category: Tools
Bought and Assembled a bandsaw, swapped the glad to a metal blade, and got two extra batteries for the portable drill


 
Jul 02, 2022     Larger Clamps - (.5 hour)       Category: Tools
in order to clamp some items for the main spar assembly i needed clamps with more clearance than the 6 inch clamps so we got a par of 9 inch clamps and those did the job.


 
Jul 02, 2022     Replacement Hardware - (1 hour) Category: Wings
Replacement screws to make up for the broken screws from removing and reinstalling the misplaced spar attachement point, and extras that will be needed to attach the rib to the location where i drilled the holes that will no longer be viable for rivets.

Took about an hour due to identifying number and types of screws then ordering it all on WBPartsExpress only to see 40 dollars for a shipping charge so instead i went to Aircraft Spruce as their shipping was only 3 bucks a little more expensive per unit but i was going to pay more for shipping than the parts.
 
Apr 30, 2022     Left Main Spar (Plus What Might be a Big Oppsie) - (6.5 hours)       Category: Wings
Did most of the work i needed to on the left spar prior to mating with the right spar for final items, Then i realized that i placed the root rib attach angles in the wrong place, This might compromise the spar and also ruins the primary way to attach rib 1 to the main spar. I have sent out an email to the factory to see if i can salvage the spar without having to replace it. but we will see what they say the oppsie is in the last 4 pics. Oh and i also striped a bolt that i ended up drilling out and replacing.


 
Mar 05, 2022     Sawhorses - (.5 hour)       Category: Tools


 
Mar 05, 2022     Main Spar Component Preperation - (2.7 hours)       Category: Wings
Had to drill and clean up Main Spar Attachment blocks and related items. I also unboxed the main spars but need to pick up some sawhorses to continue building out the spars due to the length of the spars.


 
Feb 27, 2022     Aileron Bellcrank Assembly Part 2 - (4.5 hours)       Category: Wings
Finished assembling the aileron bellcranks this took some finessing as i had to work on getting ample clearance of the bell crank once everything was assembled. Once the aileron bellcranks were done i worked on the the aft rib assemblies that hold the aileron bell cranks.


 
Feb 03, 2022     Ordered Duckworth LED Landing/Taxi Lights - (.5 hour)       Category: Lighting
Ordered 2 LED Landing Light Kits from Duckworth Aviation.


 
Jan 29, 2022     Aileron Bellcrank Assembly Part 1 - (3.5 hours)       Category: Wings
Started to assemble the bell cranks and prep the left side bell crank assembly, unfortunately when trying to ream a hole using my drill press i realized it had some runout and what should have been a press fit hole became a loose fit hole, I suspect i will need to replace the part so that will probably be another 30 dollars since it is a machined part but waiting on the factory to give me some advice.


 
Jan 25, 2022     Ordered Air Data Sensors - (.5 hour)       Category: Avionics
Ordered a heated and regulated version of the Garmin Gap 26 Pitot as well as a mounting kit, a cover for the pitot tube, and two static ports.


 
Jan 25, 2022     Ordered 3in1 Lights - (.5 hour)       Category: Lighting
Ordered a set of Aveo 3 in 1 Nav/Pos/Strobe Wingtip lights.


 
Jan 22, 2022     Foward Wing Ribs - (6.7 hours)       Category: Wings
Created Rib Reinforcements, and then attached and riveted reinforcements in addition to deburring all forward wing ribs.


 
Jan 22, 2022     Updating Drawings - (1.0 hour) Category: Research
Scrubbing all drawing updates to ensure we are building to the latest specification.
 
Jan 10, 2022     Ordered Canopy Latch - (1.0 hour)       Category: Canopy
Ordered the Canopy latch made by Peter with the carbon fiber reinforced handle.


 
Dec 17, 2021     Purchased Vans Vent Kit - (.2 hour) Category: Fuselage
Ordered the vans RV 14 vent it, it is a little more effective and has cleaner controls than the sonex model i will just adapt them to the sonex fuselage when we get there.
 
Jul 18, 2021     Aft Rib Assembly 2 - (3.00 hours)       Category: Wings
Continued Assembling Aft Ribs 1 set left to assemble, 14 Additional Ribs to clean up.


 
Jul 07, 2021     Reamer Set Ordered - (.2 hour) Category: Tools
several holes require press fit and or precise holes particularly in the control bell cranks and other items that take oil impregnated bushings so I had to order a set of reamers to that those holed are precise
 
Jul 04, 2021     Aft Rib Assembly 1 - (6.5 hours)       Category: Wings
Assembled 4 of the needed root rib assemblies with the extra stiffening doubles. Doublers also needed to be fabricated from flat stock


 


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