Project: BattenWaiex   -  
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Builder Name:William Batten   -  
Project:   Sonex - Waiex-B   -   VIEW REPORTS
Total Hours:653
Total Flight Time:1
Start/Last Date:Apr 26, 2022 - No Finish Date
Engine:Jabiru 3300
Propeller:Prince P-Tip 54/62
Panel:MGL Avionics
 
Friendly URL: https://eaabuilderslog.org?s=BattenWaiex

Home or Last Project Picture

May 05, 2024     Ram Air Cooling Ducts - (3 hours)       Category: Engine
Jabiru supplies fiberglass ram air cooling ducts for the engine. Unfortunately these ducts are designed to match the Jabiru aircraft - not a Sonex. The Sonex cowling is very small compared to most aircraft - so, these ducts were both too long and too high - they did not fit inside the cowling as received. I'm making significant modifications to the ducts to make them fit.


 
May 02, 2024     Matching the Upper and Lower Cowl split lines - (3 hours)       Category: Cowl
Now that I have the upper cowl fitting properly onto the lower cowl - I'm working to get the split line even - upper to lower. Had to add some filler to the lower cowl in some spots - and to the upper cowl in other spots.


 
Apr 30, 2024     Upper Cowl Cleco'd - (3 hours)       Category: Cowl
The upper cowl is finally close enough that I could drill for the cleco's. Next I'll begin to fit the upper cowl to the lower cowl for a finish fit.


 
Apr 28, 2024     Wear Tabs - (2 hours)       Category: Cowl
I made some wear tabs for the cowl


 
Apr 28, 2024     Oil cooler tunnel gaskets - (3 hours)       Category: Engine
The oil cooler tunnel has a rubber gasket that will seat against the fiberglass lower cowl.


 
Apr 28, 2024     Wear Tabs Installed - (2 hours)       Category: Cowl
Because of the modification that I have made to the upper cowl - the upper cowl snaps in place under the windscreen skirt. I was concerned that this snapping action may chip the paint after a few installations. So, I have epoxied in an aluminum wear strip into each side of the upper cowl. Hopefully the aluminum will stand up well during installation.


 
Apr 05, 2024     Fitting the Upper Cowl - (8 hours)       Category: Cowl
The upper cowl fiberglass piece was actually not very well made - it did not fit to the lower cowl at all. Basically, I'm re-making the entire piece. Still a long way to go.


 
Mar 25, 2024     More modifications to the lower cowl - (2 hours)       Category: Cowl
The exhaust pipes interfered with the exhaust tunnels - so, I had to modify them. The lower cowl is now fitting well and ready for the hinge fasteners.


 
Mar 22, 2024     Epoxy with Micro-balloons - (2 hours)       Category: Cowl
I'm working on the radius around the openings in my cowl. Epoxy with micro-balloons is lightweight and easy to form. I've used Styrofoam as the filler material.


 
Mar 22, 2024     Exhaust Tunnels - (1 hour)       Category: Cowl
Exhaust Tunnels - fitted and cleco'd in


 
Mar 21, 2024     Lower Cowl - (8 hours)       Category: Cowl
The lower cowl had to be fitted to the fuselage. This required trimming along the sides as well as two clearance holes in the front - one for the camshaft cover and one for the oil line in front. Next was to install the large side outlet vents and finally the exhaust tunnels. This is still work in process - a lot of finish work still remains.


 
Mar 11, 2024     Flap Switch Resistor Matrix - (2 hours)       Category: Instrument Panel
The Flap Switch requires a resister matrix to interface with the flap controller - so, I integrated them into the wire harness.


 
Mar 09, 2024     Upper Cowl attachment modification - (3 hours)       Category: Cowl
The Sonex Upper Cowl is believed to be the single most difficult part to fit - and most importantly install. Per the drawings, the cowl is intended to fit under the windshield skirt, and then held in place by fasteners from the top. I decided to fabricate a "shelf" for the upper cowl to rest on during installation. I want the top of the cowl to align with the top of the windshield skirt - so, I needed a spacer the same thickness as the cowl. My cowl measures between .100" and .120" - so, a .125" aluminum strap is almost perfect.


 
Feb 20, 2024     Improved wire strain relief - (1 hour)       Category: Instrument Panel
Well, I showed the result of soldering with the 22 gauge wire to my friend Al. He pointed out to me that I should have added some shrink tubing over the soldered area - to relieve some strain from the wires. So, I unsoldered and soldered back - this time with shrink tubing. Of course - he was correct - this is much nicer.

You might also notice in this picture that the two middle switches are installed upside down. This is on purpose because - they are the Mag switches. When a Mag is turned off - the circuit "closes" - thereby grounding the Mag. Most switches, for lights, etc., will be "Open" when in the down position - turning off the light.


 
Mar 03, 2024     Control Stick Assembly - (4 hours)       Category: Controls
Assembled the Control Stick Assembly


 
Mar 05, 2024     Fitting the Cowl - (8 hours)       Category: Cowl
Lower cowl is fitted. I'm afraid this was the easy one. I had to cut clearance holes for my camshaft cover and one oil line. The large hole in the center is the oil cooler air inlet. All of these will be fiber glassed over prior to paint.


 
Feb 22, 2024     IP Labels - (2 hours)       Category: Instrument Panel
I completed my IP labels today.


 
Jan 22, 2024     Toggle Switch Bus Bar - (2 hours)       Category: Instrument Panel
I've fabricated a copper bus bar to feed 12 volts to all of my toggle switches on the right side of the IP. This accomplishes two things. 1) Reduced wire count - I only need to run one 12 volt wire from my master bus to the toggle switch bus. 2) Additional strength for the toggle switches - since they now have an anchor at both the front and back of the switch. You can see that I have expansion capability of two more toggle switches if needed in the future. You can also see the hole I have prepared to accept the 12 volt feed wire.

Well, I just realized that my bus bar idea will not work with the fuse block that I purchased. Too bad - I really liked the idea.


 
Feb 16, 2024     Flap Position Switch - (1 hour)       Category: Electrical
My first attempt at soldering leads to my flap switch failed. I didn't realize that the white disc was plastic - thought it was ceramic. I ended up melting the switch to the point that it was no longer functioning. Talked to my friend Al and he suggested using 22 gauge wire rather than 18 gauge wire - that did the trick - success.


 
Feb 09, 2024     Fuse Blocks Installed - (1 hour)       Category: Electrical
Master fuse block and the Avionics fuse block.


 
Feb 08, 2024     Finishing the NACA Fresh Air Ducts - (3 hours)       Category: Fuselage
Today I smoothed all the edges around the fresh air duct opening and installed the Peter Anson fresh air ducts.


 
Feb 09, 2024     NACA Fresh Air Vents Completed       Category: Fuselage
Here you can see the NACA shape cut into the fuselage. NASA developed this shape back in the 1950's as a method to minimize induced drag.


 
Feb 08, 2024     Transponder Antenna Mount - (1 hour)       Category: Avionics
I placed a small doubler plate under the transponder mounting area - bottom of the fuselage.


 
Feb 07, 2024     Rough cut-out for the "NACA Fresh Air Vent" - (2 hours)       Category: Fuselage


 
Feb 07, 2024     ADS-B Antenna - (1 hour)       Category: Avionics


 
Jan 11, 2024     Hydraulic Hoses - (4 hours)       Category: Engine
Firewall side hydraulic hoses are complete. Two for the oil cooler and two for fuel. Fire Sleeve installed over the braided steel hoses.


 
Feb 03, 2024     Fuel Hoses - (4 hours)       Category: Fuel System
Fuel Hoses in the Engine Compartment


 
Feb 03, 2024     Throttle and Mixture Cable Firewall Pass-throughs - (1 hour)       Category: Engine
These pass-throughs will hold the throttle cable and mixture cable.


 
Jan 29, 2024     Antenna Doubler Plates - (2 hours)       Category: Avionics
I've fabricated 4 doubler plates - to go under the 4 antenna's. The two small one are made from 0.025" aluminum and will be for the transponder and ADS-B antennas - both of which are about 3" long. The two larger doubler plates are made from 0.032" aluminum and are for the com and ELT antennas - both of which are about 21" long and will create significantly more stress to the fuselage skin.


 
Jan 26, 2024     3M Vinyl applied and Instruments Installed       Category: Instrument Panel
I purchased a 3M vinyl wrap call Di-Noc with a carbon fiber texture. This stuff looks really convincing. Had a chance to put all of my instruments into the panel - except for the ELT panel switch. Holding off buying the ELT until the last minute.


 
Jan 21, 2024     Panel Cutouts Complete - (8 hours)       Category: Instrument Panel
It's been really cold this week. So, I brought home a few projects to work on in the garage. Instrument Panel cutouts are now complete.


 
Jan 21, 2024     Final Panel Layout - (12 hours)       Category: Instrument Panel
This is my final panel layout. I gave this task 12 hours - but honestly - it was much more. I've made revisions to this drawing dozens of times - hopefully each one a little better. My logic was - I'll be flying with my right hand - therefore, most everything else must be performed with the left hand. Throttle, Mixture, Trim, Flaps & Radio. So, I made sure that each of those devices were in easy reach of my left hand. Lastly, the switches on the bottom have a logical order - left to right - as I go through start-up, taxi and take-off.


 
Jan 12, 2024     Paper Layout for the IP - (1 hour)       Category: Instrument Panel
I printed a full scale layout of my Instrument Panel. I plan to look at this for several days before I begin cutting any holes.


 
Jan 08, 2024     Ironwood Handle - (1 hour)       Category: Interior Finish
Close-up of the handle


 
Jan 08, 2024     Brake Handle - (8 hours)       Category: Interior Finish
It took me about 8 hours to complete this wooden handle. Having said that, it's too cold to work in the hangar this week - so a project like this worked well to complete in my garage where it is warmer.


 
Dec 31, 2023     Wood block for the brake handle       Category: Interior Finish
The brake handle is a piece of aluminum stock. I decided to make a wooden grip for this handle. This is a piece of Ironwood with a burl pattern - hope it turns out nice.


 
Dec 29, 2023     Oil Cooler Hose - (3 hours)       Category: Engine
Cut and assemble the oil cooler hose - then install the fire sleeve.


 
Dec 10, 2023     Quick Oil Drain - (4 hours)       Category: Engine
The design of the Oil Cooler Baffle is a direct interference with the oil drain on the Jabiru engine. Thinking ahead - I decided to install a quick oil drain that I found on summit Racing. I'm very pleased with this result - sure I will be more pleased each time I change the oil.


 
Dec 10, 2023     12 Volt Power Bus in cabin - (1 hour)       Category: Electrical
I've decided to install a 12 volt power bus inside the cabin - against the firewall. This bus will receive power directly from the Master Relay - so, will be hot when the Master Switch is on. This bus will provide the power for everything inside the cabin.


 
Dec 09, 2023     Diode jumper across the Alternator Relay - (2 hours)       Category: Electrical
The electrical schematic called for a diode jumper to go across the alternator relay. So, I crimped the diode directly into the wire ends - and reinforced it with shrink tubing.


 
Dec 02, 2023     Engine Breather Tube and Oil Separator Installation - (8 hours)       Category: Engine
The pathway from my engine breather to the oil separator was convoluted and tight. I decided to bend a 1/2" aluminum tube for most of the routing - had to buy a tube bender. During my first trial, my friend Mike stopped by and reminded me that it is important not to have any low points in this breather tube. So, I bend a new tube that rises from the breather outlet up above the engine. then, it is a constant downstream run all the way to the oil separator. Also had an opportunity to use my Clamptite tool - very happy with the results.


 
Nov 25, 2023     Components mounted to the firewall - (6 hours)       Category: Engine
I have most of the components now mounted to the firewall.


 
Nov 24, 2023     Engine Breather Hose - (1 hour)       Category: Engine
Working on my engine breather hose. The hose fitting at the engine is .5" and my oil separator is .75". So, I had to step up the hose size at the oil separator. Had a chance to use my new "Clamptite" tool - pretty happy with the results.


 
Oct 06, 2023     3rd Try for the Voltage Regulator - (2 hours)       Category: Electrical
Well, I still wasn't happy with the voltage regulator installation. So, I took it back off - and re-made the mounting bracket.


 
Oct 04, 2023     Modified Voltage Regulator Mount - (2 hours)       Category: Electrical
I wasn't happy with the voltage regulator mount once I completed the installation - it was too close to the wire terminal block. So, I added an extension to the mount - much better.


 
Oct 04, 2023     Voltage Regulator Installed - (4 hours)       Category: Electrical
Installed the voltage regulator and fan - along with a connection block for each of the wires.


 
Oct 04, 2023     Mapping out the Firewall real estate - (1 hour)       Category: Firewall
Trying to decide where everything goes on the firewall.


 
Oct 04, 2023     AeroInjector & Air Filter - (2 hours)       Category: Engine
Temporarily installed the AeroInjector and Air Filter to check for fuel line and throttle cable routing.


 
Oct 01, 2023     Wing Tips Installed - (10 hours)       Category: Wings
The fiberglass wing tips did not fit well into the wing skin. So, I needed to add some epoxy filler to the outside edge - to get a good fit.


 
Sep 28, 2023     Battery Box - (2 hours)       Category: Electrical
Battery box is installed. Final hinge will be installed once I have the battery - to assure a snug fit. Thanks to my friend Chuck for the customization.


 
Sep 27, 2023     Wing Tip Lights - (4 hours)       Category: Lighting
Wing Tip Lights installed and ready to connect to the wing wiring harness.


 
Sep 23, 2023     Installing the wing tip lights onto the wing tips - (24 hours)       Category: Wings
My friend 3D printed me a 45 degree adapter for my wing tip lights. So, I glassed it onto the wing tip and filled in around the adapter to make it smooth. I then had to install some Rivnuts into the back side so that I would have a hard material to drill and tap for the wing tip lights.


 
Sep 15, 2023     Taxi and Landing Light Installed - (12 hours)       Category: Lighting
I completed the wiring and installed the light lens.


 
Sep 14, 2023     Aiming the Taxi and Landing Lights - (1 hour)       Category: Lighting
Went over to the hangar tonight to aim both my taxi and landing lights.


 
Sep 12, 2023     Tailwheel Pushrod - (2 hours)       Category: Landing Gear
The factory designed pushrod is marginal in design. I used an idea from my friend Dan utilizing a chromoly steel tube and heim joints. My friend Larry reminded me that since this joint sees rotation - a castle nut is required. My friend Mike also suggested that I use a locking nut for the jam nut. Turned out very nice.


 
Sep 09, 2023     Flap and Aileron Hinges Installed - (4 hours)       Category: Wings
A total of 500 rivets to install the flap and aileron hinges on both wings. 250 of those on my back - laying on a creeper.


 
Sep 07, 2023     Wire Labels - (2 hours)       Category: Electrical
I printed my wire labels on my laser printer - #6 font. Then slide them into the heat shrink tubing - turned out great.


 
Sep 02, 2023     Tailwheel Pushrod - (6 hours)       Category: Landing Gear
The factory tailwheel pushrod has experienced problems with many of the builders. Because it relies on a bolt turning inside of a small hole - it tends to expand the hole with time - creating a sloppy linkage. I borrowed this idea from my friend Dan - using a Heim joint at each end of the rod. I purchased a thick wall chromoly tube for the rod. Bent it to shape and cut it to length. Then I tapped each end to accept the Heim joints. Lastly, I purchased conical washers for the Heim joint - allowing for the movement within the joint.


 
Sep 02, 2023     Mount for the Nav/Pos/Strobe Lights - (4 hours)       Category: Wings
My friend Matt 3D printed two 45 degree adapters for me to install my wing tip lights. My wing tips are slanted in at a 45 degree angle - so, I need this adapter to bring my wing tip lights out to the end of the wing and be vertical.


 
Sep 02, 2023     Flap and Aileron Hinges - (4 hours)       Category: Wings
Ready to install the flap and aileron hinges.


 
Sep 02, 2023     Customized Battery Box       Category: Firewall
My friend Chuck in Anderson customized by battery box - including my "N" number.


 
Aug 29, 2023     Preparing for the wing root seal - (4 hours)       Category: Wings
I plan to use the wing root seal from Van's. This rubber seal requires a 3/6" gap between the wing root and the fuselage.


 
Aug 27, 2023     Wiring for the wing lights - (2 hours)       Category: Lighting
I ran the wires for my landing light, taxi light and the Nav/Pos/Strobe lights. I've installed a connector at the wing root so that I can remove the wings as needed.


 
Aug 27, 2023     Pitot Tube Installed - (4 hours)       Category: Wings
I had to cut a hole in the wing and assemble this pitot tube. Very important to have it pointed directly into the airstream.


 
Aug 24, 2023     Wing cutouts for the Landing and Taxi Lights - (3 hours)       Category: Lighting
I cut out a portion of the leading wing edge to accommodate my landing and taxi lights. I plan to use the Duckworks brackets and lens - and modifying them to accept the Aveo lights.


 
Aug 23, 2023     Brake Lines - (3 hours)       Category: Landing Gear
Installed the brake lines today. Needed to pass the lines through the fuselage - so I installed some rubber grommets. Held them in place with clear silicon. I'm not sure I plan to keep the tie wraps on the gear legs permanently - I may look for another solution.


 
Aug 21, 2023     Wings on to install the Landing Light, Taxi Light and Nav/Pos/strobe Lights - (1 hour)       Category: Lighting
I needed to install my wings as I prepare to install the landing and taxi lights. I want to make sur that I have them mounted at the correct angles - relative to the wing.


 
Aug 18, 2023     Both aircraft now standing on their own landing gear       Category: Workshop
Southern Indiana Sonex Factory


 
Aug 16, 2023     Wheel ends assembled - (12 hours)       Category: Landing Gear
Final assembly of the brake assemblies and the wheels with tapered bearings.


 
Aug 08, 2023     Rudder Pedals Installed - (8 hours)       Category: Controls
The phenolic bushings needed a lot of work from the Dremel tool to make sure that they moved freely.


 
Jul 21, 2023     Gear Legs Installed - (8 hours)       Category: Landing Gear
Gear Legs and axles installed. The axles require a 0.7 degree toe-in. This requires use of multiple clamps, level, angle bar and a lot of patience.


 
Jul 19, 2023     Rudder Peddle Pivot Block - (4 hours)       Category: Controls
These rudder peddle pivot blocks are made from a phenolic material. It's REALLY hard to work with - you can see that my drill bit is toast.


 
Jul 18, 2023     Brakes - (4 hours)       Category: Landing Gear
Installed the brake master cylinder - and assembled the main brake body/backing plate. The Sonex design uses a hand lever to actuate the brake - similar to a motorcycle.


 
Jul 18, 2023     Cable Fairings - (2 hours)       Category: Fuselage
Cable fairings all trimmed and ready to install. I'll install these after all of the control cables are installed.


 
Jul 15, 2023     Removeable Instrument Panel - (6 hours)       Category: Instrument Panel
The factory design is to rivet the instrument panel solid into the glare shield. I wanted to have a removeable instrument panel. So, I placed nut plates behind the instrument panel for the small countersunk screws and some larger nut plates under the panel to accept 3 AN3 bolts on each side.


 
Jul 16, 2023     Flaps are complete - (14 hours)       Category: Wings
Flaps are finished and ready to install - once I install my wings. Going into the storage room for now.


 
Jul 14, 2023     Tire and wheel assemblies are complete - (2 hours)       Category: Landing Gear
Tires mounted onto the wheel haves. These are really small tires - but, it's a small airplane. You can see the brake disc on the left tire.


 
Jul 14, 2023     Gold Cube fuel flow sensor       Category: Avionics
I ordered the wrong fuel flow sensor initially - ordered the red cube. Turns out, with a gravity feed fuel system - you need the gold cube to make sure you meet the FAA requirement of 150% maximum fuel flow to the engine. The gold cube has a larger orifice and therefore flows more fuel. The red cube might be more accurate at idle conditions - but the FAA requirement is mandatory - so, Michigan Avionics exchanged this for me - thanks!


 
Jul 14, 2023     Jabiru engine intake manifold       Category: Engine
I'll be ordering my "AeroInjector" at Oshkosh this year. Want to make sure I get the correct adaptation.


 
Jul 14, 2023     1" Titanium gear legs - (2 hours)       Category: Landing Gear
I cut the gear legs to length and drilled the first two .25" holes.


 
Jul 12, 2023     Building the Flaps       Category: Wings
For such a small aircraft - these are big flaps!


 
Jul 10, 2023     Cutting the titanium gear legs - (1 hour)       Category: Landing Gear
My gear legs were .125" too long - so, had to be cut.


 
Jul 10, 2023     Balancing the Ailerons - (2 hours)       Category: Wings
I suspended each aileron using safety wire. Then had to drill out the lead weight until the aileron was balanced.


 
Jul 10, 2023     Ailerons Completed - (16 hours)       Category: Wings
Ailerons fully riveted - ready to balance.


 
Jul 08, 2023     First Aileron cleco'd - (6 hours)       Category: Wings
Aileron up-drilled & cleco'd - ready to rivet


 
Jul 04, 2023     Aileron Counterbalance Assembly - (8 hours)       Category: Wings
These two counterbalance weights took awhile to complete. Drilling through the lead was a slow process.


 
Jul 01, 2023     Another piano hinge - this time for the ailerons - (2 hours)       Category: Fuselage
The Sonex uses a LOT of piano hinges. You can see my special rule that I made for drilling the rivet holes in the hinge.


 
Jul 01, 2023     Tailwheel Installed - (8 hours)       Category: Landing Gear
Tailwheel is mounted to the tailspring. Final linkage to be installed after the aircraft is resting on the landing gear.


 
Jun 30, 2023     Windscreen and Canopy fitted - (15 hours)       Category: Fuselage
Final trim to the canopy - fitted to the windscreen. Also installed the Peter Anson canopy latch. I'm very pleased with this latch - very high quality.


 
Jun 29, 2023     James and I building side-by-side       Category: Workshop
Two Sonex aircraft in build


 
Jun 27, 2023     Installing the Windscreen - (15 hours)       Category: Fuselage
Installing this windscreen was very tricky - really a job for two people. My friend James helped to get it started - too many moving pieces.


 
Jun 24, 2023     Removable Instrument Panel - (4 hours)       Category: Instrument Panel
The drawings call for a fully riveted instrument panel. So, once it is installed - it is not coming out. I decided I want more flexibility - so, I designed a removable front instrument panel.


 
Jun 24, 2023     Rudder stops - (1 hour)       Category: Y-Tail
My friend Larry pointed out that these rivets should be countersunk.


 
Jun 22, 2023     Top and Bottom Fairing for the Y-Tail - (6 hours)       Category: Y-Tail
Almost finished with my top and bottom fairings for the Y-tail. Used my friend Mike's Slip Roller to make the radius.


 
Jun 21, 2023     Tailwheel spring rod - (1 hour)       Category: Landing Gear
My tailwheel spring rod was .25" too long. So, I took my cutoff wheel to it - took over an hour to get through .5" titanium.


 
Jun 20, 2023     Rudder Horn Bracket - (2 hours)       Category: Y-Tail
Once I installed the rudder stops on the side of the fuselage - I no longer had full rudder travel - I had an interference with the rudder horn bracket and the rudder stops. A couple of hours with a file and Dremel - problem solved. I also had to make sure that all the radii remained constant and smooth.


 
Jun 20, 2023     Assembly complete - (4 hours)       Category: Y-Tail
Today i completed the Y-Tail assembly - Stabilators, Ruddervators and Rudder. Next is the tailwheel.


 


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