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.