WORKING ON THE CAP STRIP MAIN SPAR

I received the materiel for the Cap Strip of the Main Spar. It took me two hours to figure exactly the place of the 1/8 hole of the longest Cap Strip. Then I was able to make the shortest Cap Strip and finally, on set was done. Because I don't want to make a mistake by drilling at the wrong place, I spend my time double checking the correct position of every hole.

The 1/8 hole are pre-drill hole, the, at the finale stage, the holes will be 5/32 to accommodate the rivet as per plan.

The next step is to complet the three others Cap Strip and cut the 4130 plate used with the Cap Strip at the inboard wing spar location.

The longest Cap Strip drilled

One set of Cap Strip ready

Wing's Jig

Since most of the wing's part are done, it's time to think about the jig. Looking at the plan from Sonerai, there is different versions. If we look at the wing manual, the plan seem to be for the S2 but I have the Scale 1 plan that come with the S1 plan.

To make it square and strong, with the help of Pierre, I decided to fix the jig on the hangar wall. Also, it was decided to make the frame with 1 1/2 x 1 1/2 steel angle bar. Compared to the wood that Sonerai suggest, if it take me too long before I start the wing, the steel bar will not twist like the wood could do. 

The base of the jig is fixed to the floor with high load glue. The frame is assembled with screw and bolt so, when time come to remove the jig of the hangar, it can be stowed for futur use.

 Once the frame is done, after a 24h period to let the glue dry, I made the block support. These blocks are used to support the wing. Two support have a 2in hole. These hole are used for a 1 1/2 plumb tube   that will guide the ribs during the installation on the spar.

The jig is now completed, next step is to complete the Main Spar with the Cap Strip and then rivet it and rivet the Rear Spar to the Cap Strip.

COMPLETING THE RIBS

After almost two months out of the project, I am happy to spend some time in my hangar, looking at what was done and What should I do now!!! When you start a project like this (not really complicate), when you stop for a relatively long period it's hard to remember where you stop, what was the next step and most important, did you forget anything?

So I spend some hours reading the plans again, looking the pieces done and the building log. After that time, I was able to start again. Also, I called Pierre to know if he was available to talk about the next step as I should need his help to make sure I don't do any mistake and if he could make a tool to form the lightning hole on the spar.

By the time I could get some time to press the ribs and flange the lightning hole and form the reenforcement, I did the Cap Strip of the main and rear spars.

The rear spar Cap Strip were easy to make. But, as always, time well spent help you to make it right...

1/8in hole in the rear spar's Cap Strip

Cap Strip adjusted on the Rear Spar

Cap Strip Adjusted on the Rear Spar

Finally, my schedule is ok and I can work on the ribs. So I went to Pierre's hangar and used his press to form the reenforcement and make the flanges of the lightning hole.

Using the jigs Pierre did with MDF, I put the ribs on it with a piece of rubber and pressed it. The result is awesome and make it so well.

Placing the rib on the jig.

The rib/jig is placed in the press with a rubber on top.

The result here give you a very good job.

After the rib, it's time to work on the spar. As per the plan, I have to cut a 3" diameter lightning holes in the spar and then flange it. To cut the hole, I've used a hole saw set of 3". Then for the flanges, Pierre made a useful tool, not expansive and easy to use.

Useful tool to make the flanges.

The tool installed and used with symmetrical pressure

The result.

The spar is now ready for the next step.

Now, I have to make the Cap Strip of the main spar. The 1/8" steel plates are ordered and should be delivered soon. By the time, I will start to build the jig that will be used to build the wing...

PIERRE PLOUFFE

When you starting a project, you don't want to fail. Some of you, built your airplane alone, you did it well, you can be proud of what you realized. As a new builder, I have to admit that my project could take me many many years to complete. I don't have the equipment, tools and knowledge to build my Sonerai 1 with the perfection I want. As soon as I started to think about building the Sonerai 1, I called my friend Pierre Plouffe and asked many questions about the process. How to start, what is the best option, what about flush rivet etc... He offered to help me by drawing the Sonerai 1 with SolidWorks so we could be able to compare the dimensions, have the precision of making the different parts with a CNC and take a look of the plane elements by elements.

I met Pierre in 2012, when I was starting as Test Pilot for the SAM-LS. Pierre was working with Thierry Zibi. He drew the SAM-LS on his computer, built it and assist me during the Flight Test Program. But before this beautiful adventure, Pierre worked at Ultravia on the Pelican for 18 years improving his skill from development to Flight Test.

March 2013: Flight Test Program of the SAM-LS, Thierry Zibi - Pierre Plouffe - Raphael Langumier (photo: J-P Bonin)

June 2014: Spin Test Campaign of the SAM-LS, Raphael Langumier - Pierre Plouffe (photo: J-P Bonin)

Pierre has the aptitude you need if you want to build your aircraft and make sure the safety is the top priority. I am very proud to know Pierre.

If you need help, you want to make some parts with a CNC, do not hesitate to contact him: digicoupe.com

THE RIBS

Building the wing, I need to make the difference parts. The Spars come from SoneraiWorks and are already bent. I just needed to cut them to 88-1/8. The other parts are the ribs, he nose and main ribs. To do this, I need to make the jigs, cut the ribs and make the flange (for the first part of the process).

I as I told previously, I am not equipped to make it and I prefer invest in the precision instead of tools. So, My friend Pierre made a 2 pairs of jig. One pair used to make the flanges and the other pair to make lightning holes and the reinforcements.

THE JIGS

These jigs have been made with the CNC. Following the plan, the jigs are in the dimensions of the ribs. The material is MDF 1/2. Strong enough to form the ribs, for the nose rib, we did two 1/4in holes that will be used with two pins as guide when I install the rib and squid it to make the flanges.

For the main rib jig, we did three 1/4 holes to make sure the rib is kept in place during the process and will not move when I make the flanges with the hammer.

 

Above are the jigs for the nose ribs. Made with MDF 1/2in. The left pair are for the flanges and the right pair are for the lightning holes and the reinforcement.

 

Here are the main ribs jig.

THE RIBS

The ribs are made with the CNC. Pierre drew the ribs on SolidWorks then convert the data to a software to be used by the CNC. This provide some advantages. I ordered four 4x12ft of 0.025" 2024-T3. Because I need 100in of this material to make the skin of the wing, I use the extra 44 inches to cut the ribs in it. So I saved by buying a larger sheet of 2024-T3 and I use the maximum of the material. The software allow Pierre to optimize the position of the ribs on the 2024-T3 sheet and get less scrape.

We calculated an estimate time of 80 hours if I did all of that manually. With the CNC, I saved almost 65 hours. To make all the jigs and ribs were done in 4 hours.

CNC cutting on the ribs.

After 2.5 hours, the ribs are done. Pierre showed me how to make the flanges and I came back home. It did not take a long time before I spend the evening in my hangar making the flanges!!! It so exciting to work on the first parts of the project. Now it become reality.

I've separated the ribs in two set. The left and right. The airplane need eight nose and main ribs each sides. We made two extra ribs if bad things happen!

Eight ribs will be bent left and the other eight ribs have been bent right. To make the flanges, I use a 2.5lbs hammer with sand in it. With that, the hammer does not rebound when forming the flanges. But before, I spend some time deburring all the ribs.

 Nose ribs

Nose rib before. Extra 0.5" of the normal dimensions of the ribs to make the flanges.

 Making the flanges of the nose ribs

Nose rib after

After 2:30 hours, I finally did all the main ribs. It's very satisfying to see my job, the quality and the first parts ready.

All ribs are done!!

FROM THE BEGINNING

How I started

When I received the plans and building manuals, I started with a complete reading of the documents. Many questions came in mind and I kept it until I can understand and answer by myself to some of them.

Then, I established an timeframe, and builder log and a list of material/tools required to realize the project. The timeframe table will help me to know where I am in the project and more important, help me to figure when to get the tools and materials for the next part. The builder Log is required by the Canadian Regulation but also, it's a good document to keep a record of the building process and how I did it (for future repair if needed).

But, before starting to build some parts, you need a bench. A surface that can be used to install the airframe jigs. It must be be perfect. For the Sonerai 1, I choose to make a 15 x 2-1/2 inches.

The bench

The bench should be plan. I used a Laser to align the 4 angles.

Then, installed the 2x4 following the string.

Now, it's time to make it squared (90 degree angle at each extremity)

Covering the bench bottom and top make it stronger and will not bend.

The completion is made with plywood and MDF. The MDF can be changed when needed to keep a flat  and clean surface.

Now it's time to jump

I decided to start with the wings. By the time I red the documents, my friend Pierre start to draw the aircraft in SolidWork. Some dimensions from the Sonerai Plan are not well indicated and with the help of the software, he was able to make it work. The difficulties came from the plans that are not organized by sections. You can find drawing for controls in the same page as the ailerons and some corrections are at the end of the set. So if you don't pay attention, you take the data from the plan and then realize that the correction sheet at the end show you a different dimension.

Also, the Wing Construction Manual is written for the Sonerai 2" I realized that when I was preparing  to cut the Main and Rear Spar. The Construction Manual show 95.5in but the plan says 88-1/5in and the corrective sheet says 88-1/8in!!! So after contacting SoneraiWorks, I've got the confirmation that the 88-1/8in is the good one and the Construction Manual is for the S2 but, the step by step construction work for the S1.

Why I decided to start with the wing? Because it's made with 2024-T3 and does not need welding. I've got time to work and these pieces of metal, time to bend it and rivet. Because Pierre has a CNC, he can make the jig and cut the ribs. We calculated that I could save up to 80 hours of work just to make the jigs and ribs.

I ordered the Main and Rear Spar from SoneraiWorks. This piece is very important and I prefer to get a good one without scratches, well folded and with the correct dimensions. The spars arrived 2 week after I ordered.

THE SONERAI 1 PROJECT

In January 2016, I started to look at a plane to buy. Affordable, safe and fun to fly. I was looking at a 2 seats, this is because I would like to fly with my Daughter Léa and my two others kids (Célia and Jean-Thomas) as they wish to come with me.

February 2016, I found a Sonerai 1 for sale. It's seems to be a good plane, a racer but it's a single seat. Ok, let's take a look at it. After a 2 hours inspection, I decided to buy it. But things not always come as you wish and after two weeks waiting for the saler, I've decided to go with my own project. I bought the plan from Sonerai and started to think about building my Sonerai 1!!!

The Sonerai 1 was built in the 70's to compete in the Formula V Air Race. All the specification to meet the Formula V rules are indicated here.

I will build the Sonerai 1 exactly as show in the plans and meeting the Formula V requirement. But Performances can be increased with some features, looking at material used for the cabin, new flight instruments, prop, exhaust and aerodynamic improvement.

I am not a builder but I've got knowledges about building process and aviation engineering. Everybody has his own specialty and mine is Test Flying and aerobatic. Because I don't have the equipment to build a plane and I want to make it right, I called a friend who could help me, not only as a support but to make the different pieces with the precision I want and I need. So I called him. Without hesitation, he agreed and then, the story has begun.

Welcome to the wonderful world of aircraft construction. We will learn a lot but, will have fun and hope this blog will inspire you to start your project!!!