Jul 03, 2020     Plan Review - (16 hours)       Category: Research

Detailed review of plans and completed items to date. Noted discrepancies and items to purchase.
Questions:
- Drawing XNB-L03 Where is part XNB-L03-07 cable guide used?
- XNB-T09/T10 Part XNB-T10-05 rolled knuckle hinges were installed on the rudder rather than MS20001P3 extruded hinges.
- Check XNB-F03 rear spar fitting is accessible. Align holes and updrill to 5/16 for pins with wings attached.
+ Check XNB-F05 Aft tunnel web rivets
$ ABS-C01-03 pushrod fairing for enclosing rear marker light
$ Snap vents for wind screen
$ Wing tie downs
$ Pitot, Total Energy, and port plug from W&W
$ Silk thread for wire bundles
$ SNX-W18-03 cover plates for adding inspection ports

  Jun 08, 2020     Sonex Corrects Aileron Pushrod Parts - (0.2 hour) Category: Research

Sonex replied to aileron pushrod dimension email by shipping aileron parts. Asked for additional spoiler bushings for the new Aurora bearings that are needed for connecting aileron linkage.
Purchased four male Aurora bearings, MM-5 5/15-24.

  Jun 08, 2020     Email to Factory Requesting Aileron Pushrod - (2.5 hours)       Category: Research

Add/replace correct fasteners, washers, torque nuts to see if there is any excessive drag.

Discovered that plan sheet XNB-W07 calls out a main aileron pushrod made from SNB-C03-09 rod stock with SNB-C03-10 pushrod end fittings. The kit was not supplied with either but with a SNX-C05-05 dual stick aileron pushrod. I had purchased Aurora female rod ends and additional bushings, fitting those to the supplied dual stick aileron pushrod. The threaded end of the pushrod to the witness mark of the Aurora bearings measure 81-1/2 inches between bearing centers. The plan sheet indicates this dimension should be 89-23/32 inches.

Wrote to Sonex to clarify the 8 inch discrepancy. Sonex acknowledged the packing list error and sent the rod stock and end fittings immediately.

  May 10, 2020     Update EFIS Checklists - (0.6 hour)       Category: Research

Updated checklist screens to move common functions from the paged Info modules to the Flight module.

  May 09, 2020     MGL iEFIS Programming - (3.5 hours)       Category: Research

Additional work on designing dynamic checklists for engine start, taxi, and takeoff. The screens are designed to display the device or measurement of the checklist item. For example, showing the primary battery voltage with a "master on" list item, oil pressure with "40 psi within 30 sec" engine start item.

  Mar 30, 2019     Research Dzus quarter turn fasteners for cowling - (1.0 hour) Category: Research

Research sizing, mounting, and adjusting of Dzus fittings for cowling mount. May need some specialized tools for aligning the fasteners. May use screws and nutplates due the installation simplicity.

  Nov 10, 2018     SonexFlight Firewall Forward Seminar - (15 hours)       Category: Research

Attended the first 2018 SonexFlight Firewall Forward Installation Seminar in Lee's Summit, MO. Seminar topics included
• Sonex Aircraft FWF Instructions
• Electrical System Design
• Fuel System: Design for simplicity and Reliability
• Engine Cooling Theory: Keep those Heads Cool!
• Fitting the Cowling, and Modifying for Best Efficiency
• Baffling Tips for Success
• Tuning the AeroInjector
• Exhaust System Considerations
• Maintenance and Upkeep
The major goals of the seminar were designed to better understand the instructions provided by Sonex Aircraft, LLC (or lack of!); equip the attendees with techniques to plan reliable electrical and fuel systems; demonstrate proven refinements to cowling and baffles to keep engine temps under control; and to demystify tuning the AeroCarb.
Bob Minka assisted Jeff Schultz by flying his Sonex to the event and showing various construction points.
Cost of seminar was $395, with the balance of the expense capturing travel expenses.

  Nov 11, 2017     XNB-G05: Determine Convergence For Toe-in - (2.5 hours)       Category: Research

Determined convergence point in front of aircraft for a toe-in angle of 0.7 degrees. With a 68" wheelbase gives a centerline to inside axle dimension of 34". Tan 0.7 = 34/X, X = 2,783 inches or 232 feet. The prelim calculation indicates that the slight toe in will need additional work to arrange in a 40 foot hangar.
Worked up complimentary methods to set the wheel alignment with axles other than Sonex.

  Apr 28, 2017     Hardware Spreadsheet - (6 hours) Category: Research

Brief Description: Hardware Spreadsheet
Developed a Google Worksheet for Xenos-B hardware. Sheets updated as missed hardware is found,
Started the pricing based on Wick's website, but ultimately found Aircraft Spruce's site easier to find and order from. Used Interstate Plastics cut-to-order for Delrin(Acetal) rudder pivot blocks and Phenolic fairlead holder blocks. Aircraft Spruce did not show a 3/4" long, 1/4" dia fairlead as called for in the plans, so a 1" x 1/4" diameter was substituted. Looks like the plan sheet is in error. Needed to reorder thicker Phenolic blocks for the fairleads in the tail.

Ultimately, the parts worksheet reflected the errors in bolt lengths from the plans. Sent a note to Sonex detailing plan errors, but never saw that the errors where addressed in plan updates.

  Apr 16, 2017     Ground Instruction on Xenos - (1.5 hours)       Category: Research

Met Martin Walker at his base located in the Warrenton Airpark. Received an introduction to the Xenos, preflight, startup, and taxi to get the feel of the Xenos tailwheel's turning radius.

  Apr 01, 2017     Review Plan Set - (2 hours) Category: Research

Plan set arrived. Spend several hours in study of layout. Began highlighting items to be sourced and purchased.

  Mar 25, 2017     EAA Sheetmetal Class - (12 hours)       Category: Research

Attended EAA's Sport Air sheetmetal workshop in Batavia, OH (Clermont County Airport). Instructor was Bob Koehler. Worthwhile introduction to forming, layout, riveting sheet metal. Sporty's hosted a lunch on Saturday for the class.

  Feb 11, 2017     Variometer Research - (2.5 hours)       Category: Research

Looking at variometers and probes; configuration for mounting in stabilators. Choices are
Single probes for Total Energy, Pitot, and Static Port, All-in-one probe as shown in the factory drawings.
Vendors are Cumulus Soaring, Inc. and Wing and Wheels.
Variometers
LX EOS Speed-to-fly Variometer with GPS flight recorder, navigation, Thermal Assistant, and FLARM display for $1,295.
VariometerILEC SC-7 Variometer with Audio and Averager, $795
Probe mountST-1 8mm mount for Total Energy Probe, $30.

Wings and Wheels suggested that the triple probe has three o-rings that would be more problematic that using single probes. Looking at other TE options, like the MGL Avionics G3 series that can use TE inputs.

  Feb 10, 2017     Antenna Research - (1 hour) Category: Research

2-10-2017
VHF Communication and Navigation Antenna - Perpendicular Connector, $149.
transponderL2 Transponder Antenna. $99

A bit early to select antenna, but good to have ideas to consider.

  Feb 05, 2017     Dwg XNS-T06: Stabilator Parts Planning - (2.0 hours) Category: Research

Stabilator Construction Planning, Ribs
XNS-T06 Stabilator Substructure Details
-08 Root Rib Clip, from 1/8"x2"x2" angle
--09R, -09L R&L hand clips, from 1/8"x2"x2" angle
-12 Rib #2, from SNX-Z02-Z04 channel stock. Finished length=19-7/8" + 31/64" + 1/2" + trim allowance = 21" + 1" allowance = 22"
-13 Rib #3, from SNX-Z02-Z04 channel stock. Finished length=17-27/32" + 31/64" + 1/2" + trim allowance = 19" + 1" allowance = 20"
-14 Rib #4, from SNX-Z02-Z04 channel stock. Finished length=16" + 31/64" + 1/2" + trim allowance = 17" + 1" allowance = 18"
-15 Rib #5, from SNX-Z02-Z04 channel stock. Finished length=14-3/32" + 31/64" + 1/2" + trim allowance = 15-1/4" + 1" allowance = 16-1/4"
-16 Rib #6, from SNX-Z02-Z04 channel stock. Finished length=12-1/16" + 31/64" + 1/2" + trim allowance = 13-1/4" + 1" allowance = 14-1/4"
Stabilator channel required for a single set of ribs is 90.5".

Spar channel material SNX-Z03-02 absent from shipped kit parts!

  Feb 04, 2017     Polish Test - (.3 hour) Category: Research

Fifteen minutes of working Nushine IIF on the fuselage skin. Should have reviewed Kerry Fores EAA video (http://www.eaavideo.org/video.aspx?v=25190150001%20target=) on the use of Nuvite polishing. Obtained proper twisted wool bonnets.

  Jan 29, 2017     Study Tail Kit Plans, Stabilator - (1.0 hour) Category: Research

Tail Plans Arrive. XNS-T03 Stabilator Assembly, fabricate clamp to fit pitot and TE probe.
Parts to purchase for attachment of fiberglass stabilator tip MS24694-SS Machine Screw, qty 10 left, 10 right
MS21047 Anchor Nut, qty 10 left, 10 right
SSC-34 Flush Blind Rivet, qty 20 left, 20 right
Need a countersink tool.
Grommet AN931-3-5, qty 21 right only
The three lines are for Total Energy triple sense probes lines (https://www.cumulus-soaring.com/esa.htm#Triple_Probes) as used on the factory aircraft. Check requirement for a single like this ILEC mount
Article on Total Energy Compensation in practice, https://www.cumulus-soaring.com/ilec/TotalEnergyCompensationInPractice-Brozel.pdf

  Nov 20, 2016     Self-launch endorsment - (3 hours)       Category: Research

Dual instruction in DIMO HK 36 TTC motorglider to obtain self-launch endorsement. Some thermal hunting, three emergency return to landing 270s from 300 feet.

  Nov 20, 2016     Experiential Flight in a Sonex - (1.4 hours)       Category: Research

Examined and flew in George's Sonex N607LT in KPAN Payson, AZ. An hour flight with 0.6 as PIC.

  Aug 10, 2016     Required tools, lubricants, thread lockers for engine - (12 hours)       Category: Research

Waiting for heads to ship, painted turbo, fit turbo with oil drain. Drain flange has bolt holes that are too small for the specified fasteners. Setup intake manifold, found a straight coupling and 45 degree silicone pieces missing from shipment. Two extra silicone adapters in kit. Sonex sent missing parts and arrival within the week. Started to setup air filter to carburetor, purchased 10-32 tap for AeroInjector intake bell.

Research and purchase required tools and shop supplies. Engine stand, thread lockers, oil cooler lines an fittings purchased from Jeg's.
Ordered recommended book on Volkswagen engines "How to Rebuild Your Volkswagen air-Cooled Engine (All models, 1961 and up)" from Amazon.
In reading other builder's log entries, found it not uncommon to have leaks of stock pushrod tubes. Researched alternate push rod tube arrangements with German-mad CSP (http://www.csp-shop.com/technik/pdf/deeng/26686.pdf) highly rated but expensive at $270 USD.
Purchased red anodized 2-piece with internal O-ring seal and external springs ($90). Also ordered woven red heat shielding for spark plug covering.

  Aug 08, 2016     Full Kit Discount - (.2 hour) Category: Research

Full kit purchase discount. Subtract $2,900 from total (EAA log will not accept negative numbers).