New build in Temple, TX

[hmikey]

Glad to hear about your good experience with TV and inverter. My wife uses a CPAP machine to sleep and her being without it haunts both of us. Good info. Also I would like to see how you attached the prefab roof to the walls. Fantastic idea.Thanks. Mike

[Junkboy999]

Great build so far.

I have read a thread where someone else did the preformed Front curve. But the roof and front part is a great idea. Love the Sonex too. Keep up the great work.

[TxDave]

Thanks for the kind words, folks.

Mike...the prefabbed roof was lowered into place with a couple of 1x2's attached to the spars. We then just glued and screwed it to the walls.

Today, I went over every seam with the same roofing sealer I used on the underside of the floor. Any remotely possible entry point for water will get sealed with the sticky black stuff. I also removed all of the screws used to install the roof substrate (1/8" plywood) and filled all of the holes.

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[TxDave]

Well, Christmas is over, and its back to work on the camper. We pretty much finished the galley area this weekend. The lower right cabinets contain all of the electrical stuff including the battery. I was going for nice simple lines.

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[ragincajun309]

Dave,

Your build is looking really good, I went with a similar profile I just rounded off the back. You mentioned on your previous build you used Filon on the exterior, are you planning on using it again? If so, do you have a build journal from your past project showing the Filon install? I am kicking around exterior skin ideas and Filon has just gained my attention.

Also, are the spars of your roof on 16" centers? The prefab idea looks like something I may consider.

Thanks

[TxDave]

Thanks for the kind words, ragincajun309. I did not do a build journal on my Filon covered camper. The Filon is actually pretty easy to work with. We attached it to the plywood with contact cement. Just make sure its aligned properly because once it sticks it is stuck for good. Shipping is cheap because they can roll it up and ship it in a cardboard tube by regular UPS or FedEx. Its very durable and looks great. I went with aluminum on my current build because I wanted it to be red. I will probably use Filon on a future project.

My roof spars are on 10" centers except where the roof vent fan is boxed in.

Dave

[TxDave]

I finished my wiring today. Yahoooo! It always surprises me when I complete a relatively complicated task and everything actually works.
I used a WFCO power panel. It has all of the fuses and circuit breakers, and a 3-stage battery charger. Makes for a nice clean installation. The manual was pretty much useless for help with installing the thing. I relied mostly on the wiring diagram on the unit itself. The last photo is of my little helper, Lucy. She is a rescue who was dumped in a field. Weighs a whopping 4 pounds.
Hope everyone has a Happy New Year.

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[KCStudly]

Cute pup. I bet she is fiercely loyal.

Nice clean install on the power center, too.

[Gold5one]

I remember the original Sonex design- VW powered- fast handling. I wonder how fast the new jet goes? It's a kit you finish yourself, hopefully before you get too old to pass a FAA medical. I sold my last airplane in 2006- a Cherokee 140. No more flying- unless I have to escape the zombie horde.

[TxDave]

This little Harbor Freight 1/4" router is one of my favorite tools. I have used it on aluminum, plywood, hardwood, Formica, and Filon. I have a big Craftsman router, but 90% of the time I use this little one. In this photo I am routing out the opening for the driver's side window. Note: the blue prepainted aluminum is covered with a protective plastic coating. It is really bright and shiny underneath. Yes, I know I have been saying red aluminum skin. The wife won out on this, so I went with blue instead. Next one will definitely be red.

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Unfortunately, using a router on aluminum creates an unbelievable mess. There were aluminum shavings everywhere.

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The window and door will be installed next.

Gold5one...my airplane is the original Sonex. I'm 60 years old and have been flying since I was 16. The Sonex is without a doubt the most fun to fly airplane I have ever flown. The jet is cool, but expensive.
http://youtu.be/AK-9Nn8rcLQ

[Graniterich]

Are you free handing that cut, never used a router before

[Gold5one]

I'm 60 years old and have been flying since I was 16

Me too! I started working at the airport when I was 16 for an aircraft broker- I was a detail boy and he gave me discounted flying lessons- helped the CAP strip an Ercoupe in exchange for ground school classes. I almost enlisted to be an army helicopter pilot-- 1969- my father talked me out of it, which might have saved my life.

[aggie79]

Are you free handing that cut, never used a router before

I'm hesitant to comment since this isn't my thread but as a general rule you almost never free hand cut using a router only. You need to have some way of controlling the router while cutting. One way is to use a pattern/template and a bushing in the router base or router bit with a bearing. The bushing/bearing is held against the pattern/template to make the cut. My guess is that for the picture you were referring to the opening served as the pattern/template for the cut in the aluminum. Another way, to route in a straight line, you can use a guide as a fence. The outside edge of the router base is held against the fence to cut in a straight line. The last way is to use one of several types of guides that mount to the router or router base to control the travel of the cut. An example of the is a trammel or "compass" to cut curves or circles.

Now back to the topic.

[TxDave]

I used a laminate trimming router bit with a bearing using the window opening in the wall as a guide. Pretty much no way to mess that up. I definitely could not do it free hand.

[Graniterich]

That is what I thought, free handing wasn't the norm. I see now that the door was probably cut, and was the guide. Thank you