Sonex Builders & Pilots Foundation
A type club to promote safety and education
in building and operating Sonex aircraft.


Tips & Tricks Links

What kind of tips and tricks did you learn or would you share with a new builder?

Send your Tips and Tricks or web links here!


From member Mike Smith:
Make your own drilled bolt shank: ... 730&row=23

Remote battery charging port: ... 107&row=77 ... 069&row=72 ... 070&row=71

Self Sealing Canopy Seal:
- Got this one from Dudley Foster. ... 003&row=79 ... 004&row=78

Lightweight Portable Wheel Chocks: ... 884&row=86

Canopy Locking Pin: ... 05&row=153 ... 65&row=152

Fuel Shut Off:
- I've never seen one that's better, IMHO :-) ... 79&row=418

Labeling every single wire in the plane, at both ends: ... 33&row=571

Fuel Overflow Pan & Drain: ... 84&row=751 ... 83&row=750 ... 75&row=748 ... 75&row=736 ... 60&row=734 ... 54&row=733 ... 63&row=728 ... 78&row=727 ... 06&row=726

Spoonworld Tool tips

Spoonworld Sonex tips and tricks page

Spoonworld Workshop tips

Sonex Videos

Simple small fairings

Cutting aluminum with a bandsaw

Filing aluminum

Homemade dimpling tool

Trimming Aerovee Push Rods

Bending aluminum plate with a press

Build your own bending brake

Removing powder coating

Prepping the fuel tank

Closing aluminum angle

Aerovee Ignition Timing

Drilling titanium gear legs

Polishing aluminum

Aerovee valve adjustment

Cutting and adjusting the canopy

Drilling holes in plexiglas

Bending aluminum angle with a wrench

Making sheet metal ribs from scratch

Making a sheet metal rib from scratch part 2

Making a sheet metal rib from scratch part 3

Making a sheet metal rib from scratch part 4

Making a sheet metal rib from scratch part 5

Making a sheet metal rib from scratch part 6

Blue lining a rib

Piano Hinge

Drilling out rivets

Drilling and hole preparation