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Gavin's Sonex B
France
Registrace 15. 11. 2019
Hi - I'm Gavin and I'm building a Sonex B Ultralight aircraft in France !
As I progress with the build I am going to add some videos so that you can see my what I've been up to.
If you've got any questions or suggestions, please feel free to contact me and I'll do my best to reply.
I'm starting on the 1st November 2019 and hope to have it finished for summer 2021.
So - OFF WE GO !! ............
As I progress with the build I am going to add some videos so that you can see my what I've been up to.
If you've got any questions or suggestions, please feel free to contact me and I'll do my best to reply.
I'm starting on the 1st November 2019 and hope to have it finished for summer 2021.
So - OFF WE GO !! ............
Gavin's Sonex B Part 80 - Engine baffles Part 2
Gavin's Sonex B Part 80 - Engine baffles Part 2
zhlédnutí: 505
Video
Gavin's Sonex B Part 79 - Assembling ans installing the engine baffles -Part 1
zhlédnutí 456Před 5 měsíci
Gavin's Sonex B Part 79 - Assembling ans installing the engine baffles -Part 1
Gavin's Sonex B Part 78 - Finally fitting the pushrods, finishing touches to the engine.
zhlédnutí 548Před 5 měsíci
Gavin's Sonex B Part 78 - Finally fitting the pushrods, finishing touches to the engine and Andy's brakes - Who's brakes are upside down !!?
Gavin's Sonex B Part 77 - Making up Stainless Steel braided oil pipes with AN fittings.
zhlédnutí 389Před 6 měsíci
Gavin's Sonex B Part 77 - Making up Stainless Steel braided oil pipes with AN fittings. AND problems with my JBA Falcon.
Gavin's Sonex B Part 76 - Wiring diagrams and wire sizes
zhlédnutí 279Před 6 měsíci
Gavin's Sonex B Part 76 - Wiring diagrams and wire sizes
Gavin's Sonex B Part 75B - Extra Extra - Instrument Panel fitted !!
zhlédnutí 332Před 6 měsíci
Gavin's Sonex B Part 75B - Extra Extra - Instrument Panel fitted !!
Gavin's Sonex B Part 75 - Completing the instrument panel
zhlédnutí 421Před 6 měsíci
Gavin's Sonex B Part 75 - Completing the instrument panel
Gavin's Sonex B Part 74 - More work on the Instrument Panel
zhlédnutí 332Před 6 měsíci
Gavin's Sonex B Part 74 - More work on the Instrument Panel
Gavin's Sonex B Part 73 - Working on the Instrument Panel
zhlédnutí 414Před 7 měsíci
Gavin's Sonex B Part 73 - Working on the Instrument Panel
Gavin's Sonex B Part 72 - Making the new throttle system.
zhlédnutí 475Před 7 měsíci
Gavin's Sonex B Part 72 - Making the new throttle system.
Gavin's Sonex B Part 71 - Modification/redesign of the cockpit throttle system.
zhlédnutí 430Před 7 měsíci
Gavin's Sonex B Part 71 - Modification/redesign of the cockpit throttle system. New turbo oil filter.
Gavin's Sonex B Part 70 - AeroVee Turbo Build part 12 - Oil pipes, Turbo install, Inlet manifold
zhlédnutí 486Před 8 měsíci
Gavin's Sonex B Part 70 - AeroVee Turbo Build part 12 - Oil pipes, Turbo install, Inlet manifold and CHT sensors.
Gavin's Sonex B Part 69 - AeroVee Turbo build Part 11 - Firewall, Exhaust & Turbo Cooling
zhlédnutí 510Před 8 měsíci
Gavin's Sonex B Part 69 - AeroVee Turbo build Part 11 - Firewall, Exhaust & a look at the Turbo cooling components.
Gavin's Sonex B Part 68 - AeroVee Turbo build Part 10
zhlédnutí 346Před 9 měsíci
Gavin's Sonex B Part 68 - AeroVee Turbo build Part 10 - Modifying the exhaust and fitting components to the firewall.
Gavin's Sonex B Part 67 - AeroVee Turbo build part 9 - Problems with the exhaust manifold
zhlédnutí 489Před 11 měsíci
Gavin's Sonex B Part 67 - AeroVee Turbo build part 9 - Problems with the exhaust manifold
Gavin's Sonex B Part 66 - Making and installing the Tail Fairing Panels
zhlédnutí 311Před 11 měsíci
Gavin's Sonex B Part 66 - Making and installing the Tail Fairing Panels
Gavin's Sonex B Part 65 - Finishing the Canopy and Tail Tips
zhlédnutí 430Před 11 měsíci
Gavin's Sonex B Part 65 - Finishing the Canopy and Tail Tips
Gavin's Sonex B Part 64 - Fitting the Tail Tips
zhlédnutí 408Před rokem
Gavin's Sonex B Part 64 - Fitting the Tail Tips
Gavin's Sonex B Part 63 - Trimming the Canopy
zhlédnutí 572Před rokem
Gavin's Sonex B Part 63 - Trimming the Canopy
Gavin's Sonex B Part 62 - August 2023 Update - Wheel / Braking Upgrade plus first look at the canopy
zhlédnutí 826Před rokem
Gavin's Sonex B Part 62 - August 2023 Update - Wheel / Braking Upgrade plus first look at the canopy
Gavin's Sonex B Part 61 - AeroVee Turbo Build Part 8 - Looking for any problems inside the engine.
zhlédnutí 480Před rokem
Gavin's Sonex B Part 61 - AeroVee Turbo Build Part 8 - Looking for any problems inside the engine.
Gavin's Sonex B Part 60 - AeroVee Turbo build part 7 - Continuing to strip down the engine
zhlédnutí 575Před rokem
Gavin's Sonex B Part 60 - AeroVee Turbo build part 7 - Continuing to strip down the engine
Gavin's Sonex B Part 59 - AeroVee Turbo build part 6 - Progress then DISASTER !!!
zhlédnutí 616Před rokem
Gavin's Sonex B Part 59 - AeroVee Turbo build part 6 - Progress then DISASTER !!!
Gavin's Sonex B Part 58 - Problems with the AeroBrakes and the AeroVee Extended Oil Sump
zhlédnutí 699Před rokem
Gavin's Sonex B Part 58 - Problems with the AeroBrakes and the AeroVee Extended Oil Sump
Gavin's Sonex B Part 57 - AeroVee Turbo build part 5 - Rockers and Push Rods
zhlédnutí 768Před rokem
Gavin's Sonex B Part 57 - AeroVee Turbo build part 5 - Rockers and Push Rods
Gavin's Sonex B Part 56 - AeroVee Turbo build Part 4 - Oil Pump, Cylinders and Heads.
zhlédnutí 499Před rokem
Gavin's Sonex B Part 56 - AeroVee Turbo build Part 4 - Oil Pump, Cylinders and Heads.
Gavin's Sonex B Part 55 - AeroVee Turbo build part 3 - Crankcase assembly
zhlédnutí 478Před rokem
Gavin's Sonex B Part 55 - AeroVee Turbo build part 3 - Crankcase assembly
Gavin's Sonex B Part 54 - AeroVee Turbo build part 2 - Crankshaft and Crankcase preparation.
zhlédnutí 406Před rokem
Gavin's Sonex B Part 54 - AeroVee Turbo build part 2 - Crankshaft and Crankcase preparation.
Gavin's Sonex B Part 53 - AeroVee Turbo Build Part 1 - Cleaning and preparing the crankcase.
zhlédnutí 669Před rokem
Gavin's Sonex B Part 53 - AeroVee Turbo Build Part 1 - Cleaning and preparing the crankcase.
Gavin's Sonex B Part 52 - It's finally on it's own wheels !!
zhlédnutí 526Před rokem
Gavin's Sonex B Part 52 - It's finally on it's own wheels !!
Hello Gavin, In your last answer in this comment flow you wrote that you met some health issue. So first of all, I wish you a quick recovery. I have watched all your videos and greatly appreciated them ! Now I just ordered a "Complete airframe Sonex B kit" with the 80 hp Aerovee engine. Unfortunately, the lead time is now very long (16 to 20 weeks !). So I've plenty of time to complete my workshop installation ! I leave in France, now in Les Vosges, and I'd be interested to exchange with you when you'll be available. I wish you the better, Francis
Hi Gavin, where are you!???
Unfortunately, due to the pressures of work and some ongoing health issues, I haven't touched the Sonex since the beginning of April. I'm in hospital again this week for another surgery but I will do an update video in the next two weeks as you are not the first to ask. I will get there in the end 😊
@@gavinssonexb I wish you a quick recovery.
If you haven't already figured out the baffle trimming issue, this is how I would do it. Using sheet aluminum, make a template of only the top center portion of the cowling that matches the curve of the cowling. You will be able to see how to trim the baffle without interference from the sides of the cowling. Trim the aluminum baffle until there is a 0.75 to 1-inch clearance between the top edge of the baffle and the template. Then use the 2-inch baffle material as previously suggested so that your trimming does not have to be precise.
Use the 2 in flat baffling material, instead of the Sonex supplied and then you have a margin of error
Smart move on the catch can, because the stuff that collects in the cans is nasty
Try putting paper clips on the alum baffle. Place the cowling back on, and it will push the paper clips down to the correct height.
Just following on from @anthonystrawbridge and his fine suggestions. I was pondering the trimming of the impossible to see baffle. Could you 3D print a spacer, or multiple spacers that sit in various places on the upper edge of the aluminium sheet with a sliding indicator built into them? Sort of a spot profile gauge where when you take off the upper cowl the spot gauges all indicate how far they’ve pressed down. Then approach the critical seal gap in increments as you get near to the desired gap? I’m sure this sounds much easier from the ‘General’s Armchair’ than it would be in reality … I was starting to think the baffle you’ve built was going to be such a good seal that the vent hole wasn’t going to be big enough to equalise the air pressure 😂
Do you think the small gap that you covered is there for the purpose of evacuating heat from the exposed exhaust pipe?
That is a very good question that had crossed my mind. I will ask Sonex 🤔
Will the inner rim of the prop hub spinner spacer spin with the prop? If so, will the inner ridge that you made to rest the cowling rub on the cowling as the spinner spacer spins?
The alignment spacer is only used whilst installing the cowling to ensure correct alignment with the prop hub. It then gets a new life as a door stop or perhaps an interesting piece of wall art 😊
Now that is brilliant!
You're supposed to heavily oil the blue nipple when installing it to not damage the rubber part of the hose. Also make sure all manufactured hoses are fully flushed with mineral spirits and compressed air so there is no remaining residue or any loose flaps of rubber possibly restricting flow.
Summit Racing Parts here in the USA supplies millions of hot rodders testing and developing these hoses ( manufacturers). John did a great going with this discount material: I compared it to my favorite supplier ( Eaton Aeroquip a local aerospace hose manufacturer faa pma rated). I'm pretty happy with this pricing, John did a good job sourcing a lower cost hose with the added benefit of hot rodder race track reviews. But yeah, Im a Parker Hannifin and Eaton fan but seriously the cost isn't warranted with the Sonex.
Why on earth would they suggest filing away a portion of the rocker when a new pushrod fitting is the correct answer? Thats ridiculous. Good on you for not taking the bad advice, Gavin. I also agree with you that the bleed nipple should be on top. I dont know how you would bleed air from the line if its on the bottom. If it were me and I wanted to install wheel pants, I'd edit the wheel pants to accommodate the ability to bleed the system, not the other way around.
Stumbled into this, nice work well explained, look forward to the next!
Given the long history that Sonex has with the VW engines one would think that they have worked out any errors in the design and are able to deliver a complete and correct engine kit consistently. Based on issues that you have seen this does not seem to be the case. I love the aircraft but I am inclined to install a factory built engine.
That a BS reply from Sonex. They need to do the right thing and refund your money or send the correct parts. They also need to take those pushrods out of inventory. An engine failure could cause a catastrophic incident.
I lost a rocker arm on a new (10 hrs) certified O-200 flying in the Rocky Mountains during my initial flight training. It just poked a hole through the rocker cover and made a lot of smoke. Landed at Ricky Schroeder Field (2004). Was back in the air the next day. Nothing catastrophic. I love that airplane; it was brand new then and just recently popped up on the market. Funny, here it is twenty years later, same engine - still a nice airplane.
I'd be willing to bet the flexible brake hose between the caliper and hard brake line has broken down internally and is acting as a one-way valve. A common issue with older brake hose. Disconnect the hose and see if the piston will push back in. If it does, you know the hose needs to be replaced. It's a relatively easy fix, hopefully.
I love it, Gavin. You're definitely getting your money's worth out of your 3D printer. When I was about 19 I purchased a car from my grandfather for $1. It needed pretty much all of the steering bushings replaced, but I didn't know that before I tried to drive it home (about a 5-hour drive). It was unnerving. But once I'd replaced the bushings it drove quite nicely.
Nice solution! I managed to get the braided lines in with a VERY tight tape wrap.
3 words Gavin, brilliant, brilliant brilliant, well done…very clever and you thought completely outside the box, good on you...also congratulations on 500 hundred subscribers
Nice looking panel!
Now that the conductor length is factored to determine minimum gauge diameter we can apply a safety margin by increasing the size which provides increased circuit integrity in respect to losses which occur off paper in the actual aircraft. An example of a simple circuit might be as follows: Battery Bus (+) to Breaker Switch to Load at wing measures 18 feet. And the Load is grounded (-) at a ground bus (-) located at the instrument panel 16 feet long. So the Conductor Length is a total of 18'+16' thus 34 feet is the conductor length in this dc circuit. While a chart or formula provides the minimum gauge wire size we need to consider the circuit breaker sizes available: The wire gauge diameter must be sufficiently greater than the circuit breaker rating. In my opinion it should be sized 50% greater than the actual circuit load at minimum. ✌🏻👶🏻🚬 Just my .02 cents (2/100 of a USD)
The voice of experience is always welcome and should be respected ☺ Wise words 🙏
@@gavinssonexb Found mistakes in certified airplane wing circuits. The starter motor ground path is interesting to look at too. Obviously, the DC ground system becomes the conductor and the electrons flow from the starter case through the least path of resistance. What is it? The aluminum case, steel fixtures - just what will become the path. In the Pratt and Whitney, PT 6, some some airplane manufacturers and electrical system designers have left this to nature. Unfortunately, the electrons will flow from the starter generator through the turbine case and an arc can flash into and out from the turbine bearing......an hour later- catastrophic failure. If the designer had just insured a proper ground path using a suitable conductor like copper cable or better 2" flat braided tinned copper strap back to the battery ground.
Perfect example of 98% done only 20% more to go! Great job. Interesting to see the engine fired up and taxi tests.
Good work !
Thanks for the vid, Gavin. Your airplane is going to be Awesome! 👍
Best CZcams video series on how to build an aircraft kit from scratch. Hoping that you would add the last few videos I think to see the whole plane. I'm learning this for the first time all the way from Chennai, India. Thank you :)
Beautiful work!
Purr-fecto!
Love the SonexB logo, well done. Tom R. SNB0035
It's looking very nice Gavin. Well done!
très beau travail, bravo
Very very very nicely done Gav. I've been binging out on the air-cooled VW engine flight engine development. Interestingly, I heard a slight metalic tink noise when the engine (camshaft) was rotated and couldn't help but recall the noise you had described some time back. This was caused by the solid lifters dropping down from the case bore onto the camshaft consistent with lobe movement and lubricant in the bore. Im on the fence but leaning towards the opinion that drilling and tapping a vacuum port at each intake manifold and having two reasonably accurate vacuum gauges in the cockpit may be worth the effort. The idea is that one eould be accustomed to watching the two gauges pointers bouncing around at hot and cold idle speed. Apparently, an inexpensive dial type gauge can indicate discrepancies related to valve components. Observing the normal operating sets the stage for identifying potential problems without delay. 💛
It's looking very nice, Gavin! Nice job on the 3D modeling. And I'm impressed by your 3D printer's resolution - everything looks very crisp. Well done!
Excellent! Good balance. I'd probably add indicators either audible or visual to signal a few things but not really necessary. There's just a few warnings: Id probably install a heavier spring to the waste gate dump and set up the boost for slightly greater than 40" manifold pressure so an alarm could be useful for the two minute 40" limitation. I'd prefer a blinking or even a solid red LED indicator for low altitude or MEA. Probably a noise signal for low oil pressure set to 15-19 psi, and an oil temp LED at 225-230°f or so. Finally, Id add both: an yellow LED at 420 CHT and a red LED with buzzer at 450°f CHT. To me all these things converge quickly at precisely the wrong time and I want to be more outside the plane than inside. Truthfully, the MGL VSI tape leaves me wanting a traditional instrument and I can't help but look for the good old AHI/ASI/HSI gyroscopic turn and bank indicator even though the MGL is more than adequate. Just my .02 cents ( one hundred pennies (cent) in a USD). My gosh that was winded. Cant wait to do the engine run ups and ground runs. ✌🏻👶🏻🚬👍🏻
love your 3D printed stuff, and the quality of the print itself looks quite sharp as in It appaers you cant see the print segments. I thought about a 3D printer but dont know too much about them, so just put in off. i also thought about a gray panle, with white writing, think that will look fantastic.
Velcro….😊
No magnets….😮
Excellent panel Gavin. I am also going to use aluminum "sub panels" for switches, etc. BobDz
Looks just like what I've seen scratch built on a few Zenith. Several were fabricated from mild steel with a cross link / torque tube similar to dual carburetor linkage. I'm once again starting to think about scratch building the legacy model yetz I like the rag and tube of the Sonrtaii. Sonar trail (damn spell checker misspells everything)✌🏻👶🏻🚬
It’s never boring….always interesting to see your progress and the methods you use. I think the videos for the cowling fit up should be fun to watch!
Good Day Sir. Would you be able to post the make of the hand brake on the control stick. I was thinking of changing my braking system to that type as well?
Sir, I must say I always enjoy your videos as they are quite informative. I find it unfortunate these days that critical parts that you pay a lot of money for not only for the part but shipping costs as well are sent out prior to being inspected. Quality insurance is definitely lacking more and more these days
I really like the way it turned out, Gavin. Nice job!
Well done on the retro fit of the throttle quadrant, and not sure how I will do mine yet.
Nice solution. Please use lots of threadlocker! 🙂
Seen lots of experienced engine guys struggle with Aerovee.
Those fairings could be a nice little project made from fibreglass. Use the parts as forms or use blocks of foam.
Good job I look here as well as Facebook you rather behind on uploading to it
I’d be worried about skinning my knee on the friction nut. 💡 Would a larger diameter wheel that protrudes through the panel work? Might be easier to operate to. 🧐
I just pulled out my throttle quadrant. The bolt for the knob is a 1/4"-20 (1/4 inch diameter with 20 threads per inch). Its a very common size here in the US. I love the engineering going into this. Very cool stuff! Can't wait to see the completed parts.
Excellent stuff. I wasn't prepared for all these mods coming down the pipe lately. Toying with some personal concerns and best practices; considerations regarding the sticky nature of slides under pressure at the gate valve I'm only left wondering about the quality and length of the push pull cable. Having a strong, well routed - direct as possible, elriminating any excess bends, along with plenty of security attachments is important. I really like the push pull design and the utilization of the aero conversion throttle as a lever or sorta bell crank because it should increase authority nicely. The oil modification has me at a loss because I'm on the outside regarding oil temperatures, thermal viscosity, vari-therms, bypass modes and such...etc etc and on and on. Great thing about homebuilders is how they share their tech. I like the panel support stiffeners and attachments but straight away was visualizing flanged lightening holes or bolstering horizontally, flanging or bolstering triangles. Heading into fifty f below freezing here😊
Great to hear from you Anthony - I suppose that's why this class of aircraft in the US is called 'Experimental'. It gives the builder the chance to make subtle modifications to the design and invest some of themselves into the project. Here in France I am building to the class 'Ultra-Léger Motorisé' (ULM). Although regulated by the FFPLUM (the government approved/run ultralight association), the kit builder is responsible for observing the rules and regulations with regard to the assembly of the kit aircraft and there are no formal inspections. As long as the kit has previously been approved by the DGAC (the French FFA), the builder is only required to sign a declaration to say that they have built the kit in accordance to the instructions. It is possible to submit a major modification declaration which has to be approved with supporting documentation to demonstrate that it is safe and compliant. If you build a non approved kit or design and build your own ULM then there is a lot of paperwork to do with many sheets of stress calculations, weight and balance calcs and several inspections including getting a police officer to certify a measurement of the sound level whilst flying over him at a set height on the runway 🙂