Southern Ontario Sonerai 1

[eschrom]

Looking good. Did the ASI come from another airplane? Red line at 150 kts isn't right

 

[Steve Stephenson]

Thanks brother. No, that's the one that came with it. It's on the list but good enough for now.

 

[Steve Stephenson]

Regarding your compass; I had the same problem. The steel uprights and canopy frame were magnetized. I used a TV degausser coil and made several passes along the fuselage uprights and canopy. After that I adjusted (swung) the compass and was able to get it to within a few degrees.

Great idea. I'll give that a go. Thanks for the suggestion.

 

[CdnMedic]

Looking at your panel makes me wish my laser cutter/engraver had a wide enough working area to fit a full panel in, could really make a really nice panel with it... This is the stuff I'm day dreaming of when I should be getting ribs done.

 

[Steve Stephenson]

Looking at your panel makes me wish my laser cutter/engraver had a wide enough working area to fit a full panel in, could really make a really nice panel with it... This is the stuff I'm day dreaming of when I should be getting ribs done.

I don't know the area of your cutter but maybe you could do it in two pieces split up the centre. With fuel gauge in the middle, the seam may not be all that noticeable or you could leave a cut-out area to recess the tubing (that would look killer).

Personally, I set a goal of doing one tiny thing every day (and it doesn't matter how small the task is - progress is progress). I generally let the sequence of jobs almost run themselves. For example, I wasn't going to do anything with the panel until next year when I noticed the wiring was a mess and my altimeter was not functional - so it made me spend time in the office of the airplane where the throttle, carb heat control and, now, the floorboards will also get a renovation. So.. if you want to do the panel now, do the panel. Get back on the ribs when you want to. Or work a rib in when you're in between the other stuff that captures your imagination or maybe when you're waiting for paint to dry. Before you know it, all the ribs will be done and you're onto the spar. Set up a thread in this forum and post some pics too. We can all keep each other motivated and sharing ideas to get these little hot rods going.

 

[Steve Stephenson]

I got a chance to work on the cooling baffles finally. Like I said earlier, they are dune buggy (or something) upper cooling tins that are now modified. An angle grinder with a narrow cutting disk made quick work of removing the necessary material (front stuff). It turns out that these things are really close to the cowling when it's in place - which is great. In order to seal things up a little and allow for rubbing, I installed thick (1/4") wool felt along the edges. The felt is secured with small machine screws and nylock nuts. The plan is to have the cowling participate in directing air along the top of the cylinders that's why the closeness worked out so well.

It is important to mention that my dual ports are angled outward from the centre of the engine. They still fit under the cowling no problem and allow these aftermarket parts to fit perfectly.

Before and after pics attached. Left side. I didn't take pics of the right but will post something when they are all on the ship.

 

[Steve Stephenson]

Looking at your panel makes me wish my laser cutter/engraver had a wide enough working area to fit a full panel in, could really make a really nice panel with it... This is the stuff I'm day dreaming of when I should be getting ribs done.

Have you been on barnstormers? There's a project in Florida you should buy. Fuselage is tacked up and the wings are done.

 

[CdnMedic]

Have you been on barnstormers? There's a project in Florida you should buy. Fuselage is tacked up and the wings are done.

I did see that. With covid getting it up here would be a test. I'd like to do a single seater, but I don't think the gf would be as patient with me if she knew she wasn't going flying as well.

I had put building to the side for a little bit, my little side business got really busy around the holidays, but now back to making some small steps. I had to get my Trans Am finished for the summer, and it is now in a state where I won't need to tinker on it anymore until the Sonerai is finished. I'm that guy with a million things going on all the time. Life just isn't long enough to take it easy!

 

[Steve Stephenson]

Does anyone know if there's a problem (like advanced corrosion) when putting iron pipe next to/sleeving chromoly?

 

[Steve Stephenson]

Disregard the above. There's no compatibility issue that I can find.

I made an extension piece out of an iron pipe nipple (1/2" nominal) that increases the diameter and length of the original stick. The nipple was longer but I cut it to 7". This allows me to consider different grip options and puts the column where I want it. I've enclosed photos and a sketch. A foam grip from Schwinn (yep, I went cheap - - but it's comfortable) does the trick and I'll install a push-to-talk at the top and run the wires down through the column assembly. Total cost of the modification is less than 20 bucks.

 

[Steve Stephenson]

Just posting a shout out to Bennett Avionics in Connecticut. I needed a hard to come by part for a transponder I'm adding to the plane. Very helpful and did not rip me off. The used part I received was in great shape too. Well done Bennett!

 

[Steve Stephenson]

Used the centre spar bolts to secure a bracket that holds the transponder tray. With the fuel tank out, it was a perfect time to do this and a couple of other forward cabin items that would normally be very hard to reach. A blind encoder will also be secured to this bracket. As you can see from the photo, the transponder unit will be just under the fuel selector valve handle/arm.

 

[Steve Stephenson]

Refurbished propeller went back on today. Again, many thanks to Ed Sterba for his suggestions. Turns out this propeller in 40 years old! Tracking was spot on too.

 

[Steve Stephenson]

I picked up a blind encoder from Bennett Avionics in addition to the other parts I got earlier. I now have a complete mode C assembly that will go in this weekend. Again, the unit is in fantastic condition and the personal attention they showed for such a small-potatoes customer was great. In Canada, this will allow me to go to virtually any airport since we don't have an ADSB requirement (yet).

 

[Steve Stephenson]

Jeff at Airplane Plastics in Ohio just finished the canopy for the S1. Will be shipped next week. He made more than one - so if anyone needs one, it's in on the shelf.

 

[Steve Stephenson]

Fuel tank and battery were reinstalled today (and other associated bits & pieces). Many thanks to Seth and Auriel for their help again.

 

[Steve Stephenson]

Fuel tank vent installed. Transponder & blind encoder installed. Fuel added & cockpit is almost ready for business. First electrical tests done today on the the rewired systems - no issues. Whew! However, the battery will not hold a charge and will have to be replaced (it's old anyway). Fingers crossed for starting it this week.

 

[patmc]

Nice looking work Steve. I also have a single place. I have one suggestion you might be interested in. I had a Midget Mustang for years vented like yours and never had a problem. But on my Sonerai one, I vented mine like yours, but turned the "T" 90 degrees and vented the line along the side of the fuselage and out the bottom facing forward. I used 3/8 tubing and never had a problem. The big safety issue here is that in the unlikely event of a rollover in an emergency landing, the fuel tank won't be emptied leading to increased risk of fire. Good luck with you testing. The sonerai is a delight to fly. One other suggestion; and this one came from My DAR, was to drill a small hole after the 90 degree bend in the vent tube facing forward to eliminate the possibility of a bug or something else from plugging the vent in flight or on the ground (mud dobber).

 

[Steve Stephenson]

Great suggestions! I will implement both. Thanks very much.

 

[yaw_string]

I'm in Windsor (not too far away from Simcoe) and you are welcome anytime to have a look and hang around the hangar - there's beer in the fridge at all times (for those that are not flying) that you don't have to pay for if you turn up (but donations are welcome - lol). I have a little military service myself. There's a Sonerai II on barnstormers (at least it was there last week) out west. Needs TLC. For $6500 it's a great deal. Told a buddy of mine out west about it but he can't make a move on it.

Only planning on one coat of varnish on the IP - just enough to seal it up. Just so you know, it was a crappy piece of flooring underlay but will do the job. I'll post pics when it's installed. The old one is already out.

Yes, I'm an official member of the Poor Boys Flying Club! I will use anything that's free or really cheap and is probably airworthy or can be made to be.

We bought the one "out west"