SonexFlight: Recent Episodes
Jeff Shultz, Sonex 604
Welcome to SonexFlight. The podcast devoted to all things Sonex. SonexFlight is a monthly podcast discussing current events, news and topics of interest to the Sonex community. We aim to entertain and educate builders and pilots of Sonex Aircraft designs, inspiring them to complete and operate their aircraft safely and efficiently.
With spring finally here and new builders reading their planes for first flight, new owners getting ready to ferry their newly-purchased Sonex home, and the rest of us thinking about knocking the rust off on our own proficiency, it's time to discuss Transition Training. The Sonex Builders and Pilots Foundation published a training syllabus designed to guide pilots through the process of gaining proficiency to fly their Sonex airplanes, and satisfy their insurance requirements so they can obtain insurance coverage. We review the syllabus, talk with a new Sonex pilot who recently used the syllabus for his own Sonex transition, and offer some practical advice to those looking to train in the future.
Sooner or later it will be time to fly your new Sonex, and there are a few things that you'll want to keep in mind as you prepare for the big day. We speak with two pilots that recently passed that milestone and hear their advice for taking flight.
Each Sonex builder or owner will eventually reach the point where it's time to sell the plane. We discuss a rent experience where an owner sold the plane and hear about the thought process and logistics of how that played out.
The Sonex is a great handling, easy flying sport plane, that flys with absolutely no bad habits. We cover the techniques used on a typical pattern flight, discuss the speeds and performance a pilot will commonly see, and lay down the foundation for flying a Sonex pattern with precision.
Non-builder owners of experimental aircraft show a disturbing trend in the accident data, sometimes running into problems within the first few hours or even the flight home with their new airplane. Experience has highlighted many of the common problem areas a second owner may encounter, and we cover some key advice to keep you out of the NTSB database.
The plane is at the airport and ready to fly, but what items should a builder consider as they make the transition from a builder to an operator? We discuss the objectives, considerations and key info needed for effective project closeout.
One of the great aspects of homebuilt aircraft is the ability to customize and tailor our planes to our own interests and requirements. We speak with builder Jake Logan about his Sonex project and the custom features and modifications he implemented.
Electric power for homebuilt aircraft continues to make great strides to becoming available and practical for homebuilders of average means. Gabe DeVault walks us thru his current aircraft project as he creates an electric powered Xenos.
Sonex airplanes have always been known for light and responsive handling, but sometimes pilots want even more! For pilots wanting superior roll control, Sonex offers the "Acro Aileron" option. We describe the modifications necessary, the pro's and the con's, and help answer whether that option is right for you.
Tim Allen of AllenFlight speaks with us about his wingtip extension modification, and hear about the installation process and results he's achieved.
'90% done, 90% to go!' Every homebuilder is confronted with this truth as they near the end of the project and must accomplish a multitude of little things that have to be completed to finish out the project. We speak with a Sonex builder about running the last mile to his first flight.
It's been some months since our last conversation with Sonex Aircraft, and we thought it was time to catch up on the latest happenings. Join us to find out what's been happening at the factory and what to expect from Sonex in 2020.
Builders and pilots are always looking for ways to improve the performance and reliability of our engines and aircraft, and ensuring your aircraft's propeller runs smooth and vibration-free is a simple way to do both. We talk with manufacturer DynaVibe and cover the methodology and process of dynamically balancing your prop to help you get the smoothest engine around.
The holiday season is upon us, and this is a good time to brush up your Christmas wish list. We've put together a few items that we think would be great ideas to enhance your building and flying experience, whether you're looking for suggestions to offer friends and family for what to get for you, items that you might like to treat yourself with, or that extra special something for your project to show it how much you care!
Fitting the cowling is always a challenge, but with patience and the proper techniques it can be accomplished with minimum frustration. We cover our favorite tools, techniques and best tips to help you thru this portion of your build.
The canopy is one of the most challenging construction tasks in a Sonex project, and that’s true of most homebuilts. The job can be repetitive and time consuming, and the risk of cracking the plexiglas is always there. We’ll discuss how to tackle this intimidating task, and explain the tools and techniques that set you up for success and keep you out of the “cracked canopy club”.
Every pilot wants more power in their airplane, or may decide to try out a different engine for various reasons, and over the years a number of pilots have decided to conduct engine swaps to do just that. We’ll cover some considerations to keep in mind when replacing engines on an already-flying airplane.
AirVenture is over, and we're missing it already! The gang reviews some of our highlights from the show, and challenges encountered along the way.
AirVenture 2019 Days 1 and 2 were a blast! Here are a few samples of the things we did, people we talked to and events we enjoyed after the show.
AirVenture is here! Join us for some quick highlights from the weekend before the official start of the show.
AirVenture, the world's biggest airshow in Oshkosh, WI, is less than two months away, and it’s time to get busy finalizing plans for attending. We cover flying in, camping and lodging options, airshow events and more in our 2019 preview.
The Onex is Sonex Aircraft’s single place sportster, being roughly 80% the size of a Sonex and offering more speed and even snappier handling. Onex’s are appearing in the completions gallery more and more, and for good reason! Our guest owns both a Sonex and a Onex and is particularly well suited to describe the similarities and differences the Onex shares with the rest of the fleet.
Electronic Fuel Injection (EFI) is a popular addition to experimental aircraft engines, and offers several attractive benefits including balanced mixture distribution, lower fuel burn, increased power and general smoothness of operation. We discuss the SDS EFI system with a successful Sonex builder and the company founder, and lay out what you'll need to add EFI to your AeroVee.
Now that winter has finally retreated and spring flying weather is here for most of us, it’s time for many new projects to make a first flight after being completed during the winter building season. We discuss the important considerations to prepare yourself, prepare the airplane and refine your first-flight plan.
The SonexFlight Podcast is coming up on its third anniversary, and it’s probably past time that we formally introduce ourselves. Your hosts talk about our own aviation backgrounds, share the stories that brought us together on the podcast, and look ahead to goals and objectives we each have in the coming months.
Most Sonex pilots are flying engines that utilize permanent magnet alternators, such as the AeroVee and Jabiru. These systems are simple and effective, but can benefit from a carefully constructed electrical system that incorporates active voltage protection. Our guest Bob Nuckolls helps us dig into overvoltage protection to explain some simple practices we can use in our planes.
Now that winter is fading and flying season is kicking off, it’s time for us to have a look at our planes and get them ready for the season. Smart pilots will pay particular attention to the health and care of their engines. We review the common maintenance items that a pilot will need to consider, and offer our insights to keeping things running smoothly.
Garmin’s new G3X avionics system is targeted to the Experimental and LSA market segment, and offers a lot of bang for the buck. We sit down with Garmin to dig into this system, explaining what you’ll need for your Sonex and how much it will cost to get state of the art capability.
The Rotax 912 is a common engine choice for LSA and sport aircraft, but until just recently has been absent from the Sonex fleet. With Sonex Aircraft now supporting that option, builders are increasingly flying behind Rotax power. We speak with one of the first Rotax-Sonex pilots about his engine installation, and offer some insight and advice to pilots wishing to choose that engine option.
Drilling the wing spars to the fuselage is a final step in completing major assembly of the airframe, and may cause builders grief if not done correctly. We explain how to rig the wings accurately and painlessly, and avoid the need to remake parts from a wing rigging operation gone wrong.
Part of the fun and enjoyment builders derive from their projects is sharing them with others. Sharing can mean many things, but more and more it includes documenting the project using videos, and then sharing them online. We talk with an ambitious new builder about his videos and the goals he has for sharing his build project with others.
At some point every builder faces waning motivation, distractions and a slow-down in their building progress. This can have major impacts to the ultimate success of the project, and in the worst cases can lead to burnt-out builders and abandoned projects. We discuss our techniques and advice to keep motivation up and avoiding builder burnout.
The Jan 1, 2020 deadline to have ADS-B out installed and working is just a little over a year away, and it’s time to start thinking about getting it done. We’ll go over the options that Sonex pilots may want to consider and try to sort out the best units available for our mission set, at the best price possible.
The Sonex Builders and Pilots Foundation is the community organization that represents Sonex owners in the US, and they’ve been hard at work in the background since we last spoke with them. The Foundation has a couple new initiatives that are coming together, and we’ll talk with Mike Farley and Robbie Culver to hear about these efforts.
Builders love having many engine options to choose from, and UL Power has been supplying engines in the 100 hp range for years now. Recently they are starting to gain traction as a Sonex powerplant. We speak with Robert Helms, the US Distributor for UL Power Engines, and hear all about the features and operation of this intriguing engine.
Comfort in the cockpit is important, and really goes a long way to enhancing the flying experience. We cover our favorite techniques for heating and cooling in the cockpit, ergonomic layout, and providing those creature comforts that keep flying fun.
The UK and Europe are home to approximately 100 Sonex aircraft, with about half of those flying. Homebuilding is alive and well, and we’ll hear all about Sonex activities across the pond.
The first customer B-Model Sonex has flown, and it's a B-Model conversion of a flying airplane. We talk about the B-Model differences, making the conversion, and performance of the new plane.
Sonex Aircraft has seen growth and changes over the past several months, and we thought it was time to invite the factory to give us an update on what the company is working on, projects and priorities, and the future of Sonex Aircraft with John Monnett’s upcoming retirement.
The show is over, and we run thru our final thoughts, highlights and the trip back home. See you next year, Oshkosh!
More interviews as the SonexFlight gang makes our way around the show. There are so many people to talk with, and lots of great stuff for our planes!
Monday is the official start of the show, and it's on! With so many interesting things to see and people to talk to, we grabbed a few of the highlights to give a taste of the variety.
AirVenture 2018 is here, and the SonexFlight gang made it into Camp Sonex. Join us for a sampling of what Day Zero brought, and what you can expect at the big show!
Flying to AirVenture in Oshkosh, WI in your own airplane is one of the great privileges and thrills that pilots have, and to arrive in a homebuilt plane is even better. AirVenture (or just “Oshkosh” to most EAA’ers) is a bit overwhelming to a newcomer, especially those that plan to fly in or camp on the grounds. We discuss our best tips to make the planning and execution of your trip run smoothly, and help you navigate the experience like a seasoned AirVenture attendee.
Corvair conversions continue to find favor with experimental aircraft builders, and a growing number of Sonex pilots are now flying behind Corvair power plants. We speak with a builder about his decision making process that led him to an alternate engine, and hear about his experience building and flying behind a Corvair engine.
The AeroVee engine is a great, affordable engine option for your Sonex project. The AeroVee is an “engine kit” and requires builder assembly. A detailed assembly manual and video walk the builder thru this process, but there are areas that may be overlooked, done incorrectly or simply under-appreciated in their significance. We discuss these areas with several experienced AeroVee engine builders and pilots, and present tips to ensure your engine is built right and performs reliably for years to come.
Traditionally, the choice of Sonex finishes has been paint or polish, and each has their own merits. However, there is a new option that is lightweight, cost effective and fairly simple, using adhesive vinyl sheeting. Several Sonex airplanes sport this finish, including both John Gillis and Mike Neidenthal. John is a certified 3M applicator, and will tell us all about using vinyl wrapping on your project.
Our friends in Australia are busy building and flying their Sonex aircraft, and are doing some pretty interesting things. Although the one hundred or so builders are spread across a very large country, there are definite "hot spots" of Sonex activity. In Part 2 we speak with Chris Dearden and Peter Anson and hear about their challenges and experiences building so far from Oshkosh.
Our friends in Australia are busy building and flying their Sonex aircraft, and are doing some pretty interesting things. Although the one hundred or so builders are spread across a very large country, there are definite "hot spots" of Sonex activity. In Part 1 we speak with Peter Henry and Chris Bishoff and hear about their challenges and experiences building so far from Oshkosh.
One area that requires a bit of builder finesse is fitting the turtle deck skin to the fuselage bulkheads. There are some simple techniques that will allow that skin to lay perfectly flat on the bulkhead flanges, and produce a smooth, dimple-free surface. We’ll describe how to make your turtledeck look like it was built by a pro.
The Xenos is Sonex Aircraft’s long-wing motor glider, a derivative of the basic Sonex design. It sports a 40 ft wingspan, longer fuselage with Y-tail, and a flapless-wing with ailerons and spoilers. The Xenos is designed as a touring motorglider, and has found a small but loyal following among Sonex pilots. Our guest Dave Dooley tells us all about his Xenos and how he enjoys flying the mountains of Colorado.
2017 is in the books, and there were a number of things that stand out. We look back at some of the more significant things to occur, review a few of the popular topics we covered on the podcast, and discuss the results of the 2017 Listener Feedback Survey. Lastly, we look ahead at a preview of the year we have planned for the podcast, and finish up with our thoughts on a “Most Wanted List for 2018” of things that we’d like to see Sonex Aircraft do, initiatives to focus on, or products to develop.
Regardless of engine choice on your Sonex you’re going to need a prop to go with it. There are many choices, but the goal is the same – to get an efficient, durable, good looking prop for a reasonable price. Prince Aircraft Company is one of the best respected propeller brands available for the Sonex. Lonnie Prince tells us about his prop and how to create speed out of thin air.
Every pilot dreams of flying their own jet, especially one that is small, fast and maneuverable. Sonex Aircraft has fulfilled that dream for a handful of customers, but there’s much more potential for others to join the ranks as well! John Corneal is an early SubSonex builder and talks about how a “regular guy” was able to pull this off.
Fall is here, and for many people that means flying is slowing down and it’s time to conduct the annual condition inspection. We’ll review the areas typically inspected during a good condition inspection, and go over our best practices for Sonex-specific items that should be on your checklist.
"Camp Sonex" was formed once again, this time at the 31st Annual Fly-in at the Flying-M Ranch in Reklaw, TX! This gathering is a special event, and it's hard to describe why it's so loved by those who attend. The cast and attendees attempt to put the magic of Reklaw into words as we catch up around the camp fire.
Captain Mike "Caveman" Neidenthal joins us again as we attempt to describe the feel and personality of flying a Sonex, and to give some insight to why Sonex has such a loyal following of pilots. Simply put, we love the way they fly, and we’re going to tell you all about it!
We discuss an alternate way to bend the leading edge skins using an ordinary shop vac, rather than the complicated process of press-bending the skins. The vacuum bending technique is great for scratch-builders, or for those kit builders that have to replace their leading edge skins and want to avoid the cost of buying (and shipping) pre-fabricated skins from the factory.
Waiex builder Jim Hicke is back from his 3-week Alaska trip. This was an epic trip, filled with spectacular sights and video, unexpected rewards, and a few unpleasant surprises. We discuss Jim's highlights and his challenges, the planning involved, and lessons learned from making a big trip in a Sonex.
The process of moving from Interested Outsider to Full-fledged Builder can be intimidating as the would-be-builder conducts research, builds support for the project, and works up his or her budget. Our guest this episode did just that and recently took the plunge into building.
AirVenture 2017 is over, and it was a great show! The SonexFlight crew is back home, and we review the remainder of the show and reminisce on the interesting things we experienced.
AirVenture 2017 is under way, and 'Camp Sonex' is officially open! We report on the first couple days of the show, tell what we've seen, and what we're looking forward to seeing and doing. Oshkosh is off to a great start.
Preparing for unexpected situations starts before you even leave home. We discuss the prep that we conduct before venturing out of the local flying area, the tools and supplies that accompany us, and how the right mindset allows you to enjoy the adventure of the trip rather than focusing on the difficulties.
Bob Nuckolls is back, and we continue our discussion of electrical systems, including topics such as regulators, sources of electrical noise, and grounding practices.
We scratch the surface of practices and considerations behind designing and implementing the electrical system for your Sonex project. We’ll speak with a well-respected and recognized expert in aircraft electrical system design, Bob Nuckolls, and tap into his more-than-50 years of experience.
We discuss the process of making longer flights via Sonex, and speak with famed Sonex pilot Kip Laurie about his cross-country flying process, and how he gets the most out of his Waiex for travel.
One comment often heard from pilots is the desire for more range or endurance. This month we’ll look at a few custom solutions that have been created by builders to provide more fuel capacity, and highlight a few items to consider to start you on the right track when developing your own system.
We tackle a really tough problem – how to reduce the frequency and severity of accidents among Sonex pilots. Our discussion approaches the topic through a Sonex-specific lens, but certainly applies to all aspects of aviation.
We explore the situations where a builder may consider installing an autopilot is a Sonex project, even though the Sonex is thought of as a rather "sporty" airplane. We’ll dig in to the details of the popular autopilot offering from Dynon Avionics.
We explore the ins and outs of flying aerobatic maneuvers in a Sonex, review the types of maneuvers appropriate for a Sonex, and go over a few tips from our guest Mark Kingman to make flying acro a bit easier. In the news we discuss the NTSB's recently released Factual Report of the 2014 Sonex crash near Big Bear, CA.
We discuss the various options and consideration for choosing brakes for your Sonex project, including the stock drum brakes, optional AeroConversions hydraulic brakes, and other aftermarket brake systems. Guest Mike Farley offers his experience and insights gained from his project.
We delve into all aspects of rivets on the Sonex. We’ll discuss the types of rivets used in our construction methods, proper techniques, tools and various tips and tricks learned over the years.
We discuss the process of putting together a Pilot Operating Handbook – AKA a “POH”. We review the major considerations and a few helpful references to guide you through the development a complete and useful document. We also comment on our own individual methods of operating our Sonex, from start-up to flying the pattern.
We discuss documenting your Sonex building project, including the regulatory requirements for documentation, the various options for your logs, benefits of documenting, and tips and tricks to make the process easier.
The Sonex landing gear system is robust, effective and simple to set up, and we cover ways to make it even easier. We talk with early plans-builder Bob Mika about planning considerations for your gear configuration, challenges or issues builders may encounter, tips and tricks, and a few useful modifications.
In Episode 8 we discuss the advantages and disadvantages of purchasing a second-hand Sonex project, outline the major considerations on finding and evaluating a potential project, and offer tips and lessons-learned from builders who have successfully completed rescued projects.
We discuss tuning the AeroInector and AeroCarb. This carb is deceptively simple, but it needs to be tuned correctly for best performance. Kerry Fores from Sonex Aircraft LLC walks us thru the process, outlines common mistakes and provides trouble-shooting tips.
In Episode 6 we speak with Sonex Aircraft LLC General Manager, Mark Schaible. We discuss a wide variety of topics wit Sonex, review the latest efforts and focus areas, and talk about Sonex’s biggest challenges and frustrations. In the news we review the UK Sonex Approval Document, the recent AeroVee Turbo Service Bulletin, and more.
In Episode 5 we speak with Robbie Culver, President of the Sonex Builders and Pilots Foundation. We talk about the mission and goals of the Foundation, transition training and other safety concerns. In the news we discuss recent SonexBuilders.net threads about solving radio noise, and the Stratux do-it-yourself ADS-B receiver.
In Episode 4 we discuss important considerations to achieve good engine cooling in your Sonex. We speak with Mike Smith about his recent experiences trouble shooting and improving his engine cooling efficiency. In the news we discuss NKET-approved Xenos Motorglider Quick Build Kits and Josh Bardell's homebuilt portable air-conditioning system for his Sonex.
In Episode 3 we discuss the AeroVee Turbo engine option for the Sonex. We speak with Mike Farley and Carl Benda, two highly-experienced Turbo owners, detailing the Turbo package itself, the modifications to your Sonex to add a Turbo to an already-flying AeroVee-powered Sonex, and performance of the Turbo (Spoiler - it Rocks!). We also review current news, Forum discussions and more.
In Episode 2 we hold a round table discussion regarding fuel systems. We review what the plans call for, important considerations in designing your own fuel system, common modifications, and mistakes or pitfalls that frustrate builders. We also review recent Sonex new product press releases and recent SonexBuilders.net forum topics.
In Episode 1 we speak with a current Sonex builder and discuss his project, and find out why he chose the Sonex. In the forum news we discuss our favorite plans features and mods, discuss the Factory Waiex crash near Fond du Lac airport and the NTSB report on the Tom Huebbe fatal accident in 2014.