Sonex Material Planning Guide (for Scratch Building) - Manual

© 2012 Sonex Aircraft LLC. All
Rights Reserved. The information
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the originator who reserves all pat-
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granted to others. This document
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Oshkosh, WI 54903
Phone (920) 231-8297
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email:[email protected]
www.sonexaircraft.com
Sonex Aircraft,
LLC
About this Guide...
This guide has been developed to help you mini-
mize the material you'll need to build your Sonex
- an important part of keeping the total cost of
your project low. The accompanying illustrations
show how the parts can be laid out on each sheet
of aluminum to minimize waste. However, it is
not necessary to follow this guide to successfully
complete your aircraft.
Other things to keep in mind which can consider-
ably reduce the cost of building the Sonex are:
Shipping costs add up quickly - especially on
items which must be transported by truck. It
is in your best interest to order all of the ma-
terial at once to minimize shipping costs. At
the very least order all of the 4' x 12' sheets
of aluminum at the same time as they must be
shipped by truck.
Mistakes will occur but their effect on the
cost of your project can be minimized by
remembering that good, small parts can be
made from bad, big parts.
Some of the material needed to build the
Sonex is required in very small quantities.
You may be able to beg or buy what little
material you need from other builders in your
area. Network!
Use local sources, if available, when pur-
chasing your materials. You can avoid high
shipping costs if you can pick the material up
yourself.
Shop around! Prices vary and some suppliers
offer quantity discounts.
Though every effort has been made to make this
guide as accurate as possible, this is only a guide
and not a guarantee. If you discover significant
errors or omissions, please bring them to our at-
tention.
Note: The following materials are not included
in this list. Hardware (rivets, fittings, bolts, nuts,
etc.), 4130 steel tubing for engine mount / gear
brackets, titanium gear legs, and the spar caps
(spar caps must be purchased from Sonex Aircraft,
LLC).
SNX-B07.9
Material
Planning
Guide
Page 1 of 6
rev. C
Sept. 2000
MATERIAL PLANNING GUIDE
Material List
6061-T6 Aluminum Sheet 1
T x W x L ............................................... Qty
.025 x 48” x 144” ................................... 11 pieces
.032 x 48” x 144” ................................... 2 pieces
.032 x 48” x 72” ..................................... 1 piece
.060 x 12” x 12” ..................................... 1 piece
.090 x 24” x 48” ..................................... 1 piece
.125 x 24” x 48” ..................................... 1 piece
.190 (.188) x 12” x 36” .......................... 1 piece
6061-T6 Aluminum Bar
T x W x L ............................................... Qty
1” x 1.25” x 12” ..................................... 1 piece
6061-T6 Aluminum Angle 2
T x W x W x L ....................................... Qy.
.125 x 1” x 1” x 96” ............................... 5 pieces
.125 x 1” x 1” x 112” ............................. 4 pieces
.125 x 1.5” x 1.5” x 96” ......................... 1 piece
.125 x 1.5” x 1.5” x 48” ......................... 1 piece
.125 x 2” x 2” x 96” ............................... 1 piece
.125 x 2" x 2" x 48" ................................ 1 piece
.125 x 2.5” x 2.5” x 96” ......................... 1 piece
.1875 x 2” x 2” x 24” ............................. 1 piece
.1875 x 2.5" x 2.5" x 96" ........................ 1 piece
.1875 x 2.5” x 2.5” x 48” ....................... 1 piece
Miscellaneous
Material ................................................. Qty
.049 x .75” Sq. Tube, 6061-T6, 48” Lg. ... 1 piece
.058 x 0.5” Sq. Tube, 6061-T6, 96" Lg. . 2 pieces
.016 Stainless Sheet, 36” x 48” .............. 1 piece
Piano Hinge, MS20257P3 x 72” ............ 9 pieces 3
Aluminum Rod, 6061-T6, .5" Dia. x 72" 1
piece
1. See page 2 of 6 for aluminum sheet optimization.
2. See page 6 of 6 for aluminum angle cut list.
3. See page 6 of 6 for piano hinge cut list.