Upper left wing bolt

Drilled and reamed the upper left wing bolt. Perfect fit with the adjustable reamer.

Thinking about the wing pin handle, it is strange this isn't explained in the drawings. The pin is a perfect fit. It can only slide in and out There is no way it can rotate around the pin hole (in pitch direction). The wing pin handle rotates at the upper bolt. For a tight fit of bolts, this will of course not work, because the pin will be bent and will bite. This means the bolt holes must be enlarged. I made a drawing showing the different direction of the lower wing pin handle bolt and the wing pin bolt hole.

Left Wing

Finished dimpling and deburring the left outer wing and skin

Left Wing

Drilled all the 3/8 holes including the aileron hinge

More left wing

Left Wing

Skinning of left wing

Left Wing

Started with the left wing, and the angle bracket was wrong there too. Had to make a new one. Starting to have some brackets now :-) 7 in total, only two of them are correct.

Left wing and rear mid spar

Drilled and riveted in the left side angle bracket that were wrong, and riveted on the rear spar.

Then I remembered I have one more spar, the rear mid spar. Drilling, deburring and started stacking. The outer spars are going to slide into the mid spar. It will be interesting to see how that works out when Sonex had no measurements to give out when the brackets had to change.

Left wing

Fixed the remaining two ribs and the aileron paddle

Left wing

Riveted together the inner most rib doublers and bracket. Riveted on the outer ribs.

Left wing and the ONX-W10-03 fix

Continued on the left wing. Countersinking holes and riveting aileron brackets. Finally received the angle stock from ACS, and made new angles for the aft main spar according to this from Sonex aircraft. The description from Sonex of what is wrong and how the parts are to go together to make it right is nonexistent, and the drawings give no dimensions whatsoever. Sonex isn't even willing to send me new correct parts. Really disappointing.

The error is the pilot holes in the angle is too far down so the aft spar will be mounted too high. The result in the skin will not fit. With the new angle made, it is easy to get the rear spar to fit using some aluminium strips. The problem is getting the dimension along the aft spar correct. I used the bolt holes for the original angles, since there are no dimensions in the drawings.

Right wing rib and mid spars deburred

Deburred the left wing ribs and primed the mating surfaces. Deburred the center wing webs.

Left wing finished updrilled