3rd Owner - Sonex "A" - 9SL

Engine Dismount

Took the next step, removed existing wiring connected to the engine, Dismounted the engine and its on the bench to be worked on. The air baffles are all riveted in place, so the minor challenge is learning how to drill out rivets in thin aluminum. I have to modify anyway for the turbo and will be nice to have the side panels easily removable. Next Steps: Check clearances on the engine assembled in 2010, then remove everything. By next week should know if I need to lap the valve seats, etc.

Time spent organizing

Its been over two years that I have owned this project. And a long gap of time to not work it. Summer is getting over, outside/inside projects mostly complete that will allow me to work on the plane as time permits. Doing planning and expecting to make a lot of progress this winter.

IFR in process / BFR done

Finally got my BFR done after getting medical done and switching from 3rd class to Basic Med. Need to update the log book where I had done a lot of flying until 1.5 years ago. Have not updated the log since 12/2014, but had done much flying in the years. Have all the plane logs, so just a matter of sitting down and doing it (damn paperwork). Expenses: $100.00

Documentation

Sat down with Panel Designer to document what I have. Documented the grounding block on the rear of the panel. Made some changes to the configuration of the FlightDek D180 so it can sit on the bench and not constantly alarm. Items like current sensor where I am only using a battery for now. The existing diffuse LEDs in the panel are a sloppy fit, the plastic fittings they sit in a not tight, will be replacing those. Mostly working on minor things, getting ready for major changes. Expenses: $14,500.00

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  As currently built.

Seat and Canopy install for test fit (of me)

Checked fit and finish of seat and canopy. Went back in well and sat on a pillow to get a feel for the elbow room. Less headroom than I expected and looking at the plans the lowered seat option was done. But, it was not a thin pillow. Will ask Sonex for the seat cushion dimensions and find out if the box of leather from a seat seat airplane will be of any use to make new cushions.

Remove Panel for Bench Testing

Removed the Panel, tidyed up the cockpit. Removed dust and debrie, took a close look at everything visible. Pedal mounted brakes, fuel shut off, camera to remote LCD under panel on right side for fuel amount.

Panel Equipment - ADS-B?

Installed and mostly wired in the panel is a Dynon FlightDek D180, Garmin GPSMap 496 w/panel mount, Radio (not sure what one at the moment) and a few other items. The biggest item I need to add is ADS-B. I would like to have ADS-B in to the D180, but that might not be feasible. I like the EFIS features, the autopilot servos are installed. Lots to test/validate and finalize. I'm currently a VFR pilot and someday plan to get my IFR. Current plan is to finish out the plane by adding the Turbo and fly with existing equipment (+ADS-B). While flying the 40 hours off I will be planning the next panel to build and swap in over a few winter months. That would trigger a requirement to fly off another 5 or more hours again as I understand it. Full IFR (for a homebuilt) is the long term goal.

Getting Started - Evaluating

Purchased 90% complete July 2021. As I finally get started by storing the wings overhead, I am taking the time to evaluate what has been done, what needs to be done, and what needs to be redone (like the engine). 1) Riveting is mostly done, and done well. 2) Avionics is installed and wiring was in process. Probably not as bad as it looks (wiring and label detail are excellent and were done very nicely). But it is all going to get disconnected, tested, documented and reinstalled before I am done. 3) Final piece will be dismounting the Aerovee assembled in 2010, do full checkout, add the Turbo parts on, buy a new prop (sell the Sensenich suited for 80hp). Lots to do, lots to document, lots of reading.

Forged Pistons to replace Nikasil's

Ordered replacement cylinders for AeroVee. Expenses: $486.99

Turbo Parts

Order # 102322 at Sonex Web Store for Turbo Parts Expenses: $4,155.25

About this build

90% Complete, 90% left to do. Prior builders choose good upgrades/changes over the years, such as dual hydraulic brakes Good to excellent detail work. As the latest builder (goal is to complete in 2 years). Edit (08/29/2023) - Bwaahahaha! Many things need to be checked out, validated during the start of the process. Engine was assembled in 2010 and never run. I've got the turbo upgrade kit to put on and will do a partial teardown/overhaul at the same time. The first 1.5 years of my ownership is getting the garage ready for this unexpected purchase. Some riveting left to do, partial glass panel to complete/test. Decide how to implement ADS-B out, and if is feasible without fully investing in new glass.