By Michael Mossman
Retired commercial pilot Paul Vogel has decided to scale down on his aircraft operation and adapt to something smaller. After years of flying many types of corporate aircraft, including Indiana State Police helicopters, Vogel is transitioning to Sport Pilot, and is building a Sonex to satisfy this need. He received his Sonex kit number 971 just less than a year ago (July 23, 2006) and it is already about one-third completed.
The Sonex is an all-aluminum, two-seat tractor airplane with a low wing configuration. It's normally seen in a taildragger configuration but Vogel is building his with a nosewheel. The standard engine is a Volkswagen-based conversion, although many are flying with Jabiru 2200 and 3300 engines.
Vogel has a Revmaster Model 2100D engine, serial 3123 for the project. He will change the heads using larger valves; it will be rated at 80 horsepower using a slide-type carburetor.
The Revmaster is a modified Volkswagen engine. He had originally planned to use the AeroVee Volkswagen sold by Sonex but bought this engine instead, as he got a very good deal on it. His engine has never been run but was originally installed on another experimental aircraft that was never completed. He bought the engine with the 45 pitch X 56 diameter wooden propeller at a bargain price. His kit engine mounts will accommodate the engine.
Vogel says that the most difficult part so far has been bending the wing nose skin. Although the skin has the bend started it takes several ratchet tie-down straps to complete the bend and get it positioned to mate with the top and bottom skins at the spar rivet lines He recommends that a builder have some help for this phase of the project; there are several other phases where an extra set of hands makes the job easier.
Vogel writes that most guys start with fuselage "but since I'm limited in space I started with the empennage, control surfaces, wings then the fuselage. It is a learning process and most mistakes can be corrected by drilling out the rivets and re-doing. If a part is damaged you can fabricate the part yourself from spare aluminum included in the kit, or order a new part from the factory. The plans are for scratch builders that cut forms and bend their own parts. Factory assistance is very good; I do most of mine by email and usually get a response within an hour or two. Phone calls are fine unless they are on the line with other builders and then you have to wait. You can buy additional 6061 aluminum sheet, channel, bar and angle stock from some local racing suppliers and from sheet metal outlets in Indy, though some seem reluctant to sell to individuals and only stock the more flexible grades of aluminum. You can always get hardware and such from Wicks, Aircraft Spruce and other supply places."
The plans are designed so that a builder can start at different places in the project. They are drawn for amateur builders.
Vogel says "I've had no previous building experience, though I did complete an A&P course at Vincennes University, located in the Tech building at the Indianapolis International airport. That has helped mostly in recognizing hardware, such as bolt size, type etc. Although it helped it is not a necessary to build a plane."
Vogel considered other kits but chose this one because it primarily uses pop rivets, so he is less likely to need someone to buck rivets. Pop rivets make it easier for one person to build. He's using a pneumatic riveter set with about 90 pounds of pressure for most rivets, with slightly higher pressure for the longer rivets.
Although it's diminutive airplane, Vogel says he fits in it with no problem. "I'm 5' 11" tall and sat in cockpit of other Sonex planes with plenty of head room," he adds.
Vogel claims that he's probably spent about 400 actual building hours and hopes to complete the project in another year. So far he's spent less than $16,000 including engine and prop and hopes to get in the air for less than $20,000. Ultimately, a $20,000 airplane will be a bare bones airplane with minimal avionics. The engine management system will be digital although he may install some analog equipment. No further decisions have been made in the instrumentation.
Further complementing the bare bones approach, Vogel is undecided on a paint scheme but is learning towards a mostly polished aluminum look with some trim paint only.
Vogel hasn't reserved a registration number yet; he's not planning on any special or requested number.
Vogel concludes, "I'm in no hurry to complete the project, I've done a lot of flying and have no special flying that I want to do. I'll probably only fly locally and to adjoining states. I have enjoyed the building process though my wife is anxious for me clear out the garage so I will have to stay on it somewhat. If anyone is considering building a Sonex I would recommend doing it. Factory support is good; kits are precision cut; everything is pilot drilled; it takes minimal tools. If I can help or give any advice I'd be glad to do so."
Planning the Fly-In Circuit
July 20-22 (Fri-Sun) - Peoria IL - River City Air Expo 2007, Prairie Air Show, Greater Peoria Regional Airport (KPIA). Contact: Officemanager@prairieair.org 309-697-6757 http://www.prairieair.org
July 20-21 (Fri-Sun) - Mount Clemens MI - Selfridge ANGB Air Show, Selfridge ANGB (KMTC) - http://www.airnav.com/airport/KMTC http://www.myafd.com/airport/KMTC
July 22-23 (Sun-Mon) -Newark IL - Trike Bivouac, Cushing Field (0C8) - http://www.airnav.com/airport/0C8
July 23-29 (Mon-Sun) - Oshkosh, WI. - EAA AirVenture Oshkosh, Whittman Regional Airport (OSH) - http://www.airnav.com/airport/OSH - Web Site: http://www.AirVenture.org
July 27-29 (Fri-Sun) Dayton OH - Dayton Air Show, Dayton International Airport (KDAY) - http://www.airnav.com/airport/KDAY http://www.myafd.com/airport/KDAY
August 5 (Sun) - Caro MI - Annual Tuscola County Airport (KCFS) - http://www.airnav.com/airport/KCFS http://www.myafd.com/airport/KCFS - Information: Dawn Tinsey at 989-551-1641 or 989-233-9842
August 10 (Fri) - Cadiz OH - Hangar Picnic, Harrison County Airport (8G6) - http://www.airnav.com/airport/8G6 - http://www.myafd.com/airport/8G6 - Information: Ted Shaffer at 740 695 9806 or e-mail rc121@comcast.net
August 10-12 (Fri-Sun) - Bay City MI - Bay City Air Show, James Clements Municipal Airport (3CM) - http://www.airnav.com/airport/3CM - http://www.myafd.com/airport/3CM
August 11 (Sat) - Westfield IN - Fly-in, Westfield Airport (I72) - http://www.airnav.com/airport/I72 - http://www.myafd.com/airport/I7
August 12 (Sun) - Sandusky OH - EAA Chapter 50 11th Annual Fly-In Pancake Breakfast, Griffing Sandusky Airport (KSKY). 8 a.m. - 12 p.m. Scrambled eggs, sausage, orange juice, with unlimited pancakes and coffee. $5.00 Contact: Don Hostetler loclas@hotmail.com 440-258-1761 http://www.EAA50.org
August 12 (Sun) - Alpena MI - EAA Chapter #1021 Fly-In Lunch, Alpena County Regional Airport (APN). 10 a.m. - 2 p.m. Burgers, hot dogs, polish dogs, sloppy joe's, chili, potato salad, beans, all you can eat; menu varies. Menu varies monthly, all you can eat, $5.00. Contact: Ray Bock jimgaasch@gaasch.net 989-354-5465 http://www.gaasch.net/eaa
August 16-19 (Thu-Sun) - Chicago - Air Show & Water Show. Details pending.
August 24-26 (Fri-Sun) - Mattoon/Charleston IL - 2007 Luscombe fly-In, Coles County Memorial Airport (KMTO). 6 a.m. - 11 p.m. Forums, door prizes, Luscombe judging and awards. $0.25 gallon fuel discount for all fly-ins. Electric for motorhomes, camping & shower. Contact: Jerry Cox jerry25@consolidated.net 217-234-8720
August 25 (Sat) - Troy OH - Annual WACO Homecoming Fly In, Waco Field Airport (1WF), 9 a.m. - 5 p.m. Theme: Preserving the Past. Inspiring the Future! WACO pilots available for rides in open cockpit biplanes. Contact: Karen Purke info@wacoairmuseum.org (937)335-9226 http://www.wacoairmuseum.org
August 25-26 (Sat-Sun) - Alma MI, Gratiot Community Airshow, Gratiot Community Airport, 10 a.m. - 6 p.m. Airshow featuring Gene Soucy, Teresa Stokes wing walking, Scream'n Rebels T-6s, demo of Reno Air Race, Vlado Lenoch P-51, T-33, military static displays, rides in B-25, Grumman Goose, -51, T-6 Widgeon and more. Contact: DOUGLAS BRUSH dbrush@charterinternet.com 989-463-5500 http://home.comcast.net/~douglasbrush
August 25-26 (Sat-Sun) - Marion OH, EAA Mid-Eastern Regional Fly-In, Marion Municipal Airport (KMNN). 8 a.m. - 5 p.m. Contact: webmaster@merfi.info 740-362-2804 http://www.MERFI.info
August 25-26 (Sat-Sun) - Mansfield OH - EAA Midwest Fly-in, Lamm Regional Airport (KMFD). http://www.airnav.com/airport/KMFD - Web Site http://www.MERFI.info
August 25-26 (Sat-Sun) - Indianapolis IN - Indianapolis Air Show, Mt. Comfort Airport (KMQJ). http://www.airnav.com/airport/KMQJ - http://www.myafd.com/airport/KMQJ - Web Site: http://www.indianapolisairshow.com - Ultralight Information: http://www.geocities.com/indyflyers2/airshow.html
August 31-September 2 (Fri-Sun) - Dayton OH, Giant Scale Radio-Controlled Model Aircraft Air Show, Wright-Patterson Air Force Base (KFFO). Acrobatics by model jets, helicopters and warbirds during a three-day air show of giant scale radio-controlled aircraft on the runway behind the museum. Contact: Sarah Swan nationalmuseum.mus@wpafb.af.mil 937-255-3286 http://www.nationalmuseum.af.mil
August 31-September 2 (Fri-Sun) - Olney TX - ASC Nationals, Information: Robert Stark Rotor Wing director, 940 564 2938, FAX 940- 564-3209 or e-mail at rgstark@brazosnet.com
September 1 (Sat) - Marion IN - Fly/In Cruise/In, Marion Municipal (KMZZ). 7 a.m. - 2 p.m. Antique, classic, homebuilt, ultralight and warbird aircraft as well as vintage cars, trucks, motorcycles, and tractors. An all-you-can-eat Pancake Breakfast, all proceeds for Marion High School Marching Band. Contact: Ray Johnson rjohnson@FlyInCruiseIn.com (765) 664-2588 http://www.FlyInCruiseIn.com
September 1-3 (Sat-Mon) - Cleveland OH - Cleveland National Air Show, Burke Lakefront Airport (BKL). http://www.airnav.com/airport/BKL - http://www.myafd.com/airport/BKL - Web Site: http://www.clevelandairshow.com
September 6 (Thu) - Chicago/Prospect Heights/Wheeling IL - Business Aircraft & Jet Preview, Palwaukee Municipal Airport (PWK). Sneak preview of Embraer Legacy, Raytheon Premier 1A, Piaggio Avanti, Adam A500 & A700, Cessna, Cirrus, Diamond, Eclipse, Pilatus, Piper, Socata, Bombardier, and more. Contact: Paul Lips Paul.Lips@AirportJournals.com 866-202-0096 http://www.JetPreview.com
September 8 (Sat) - Erie IL - QC Challenger 25th Anniversary, Erie Air Park Ultralight Flightpark (3H5). On site primitive camping. Contact: Jim Robinson erieairpark@juno.com 309-659-2721 http://www.erieairpark.com
September 8 (Sat) - Connersville IN - Nulltown Wing Nuts Hog Roast/Fly-in, Nulltown Wingnuts Ultralight Flightpark (73II). http://www.airnav.com/airport/73II - http://www.myafd.com/airport/73II
September 8 (Sat) -Decatur IL - EAA Chapter 274 Pancake Breakfast, Decatur Airport (KDEC). 8-11 a.m., http://www.airnav.com/airport/KDEC - http://www.myafd.com/airport/KDEC - Infirmation: 217 795 2393 - Web Site: www.decatureaa.com
September 8 (Sat) - Newark OH - EAA 402 Fly-In/Drive-In Breakfast, Newark-Heath Airport (VTA). 8 a.m. - Noon. Breakfast. Contact: Tom McFadden EAA402@adelphia.net 740-587-2312
September 9 (Sun) - Alpena MI - EAA Chapter #1021 Fly-In Lunch, Alpena County Regional Airport (APN). 10 a.m. - 2 p.m. Burgers, hot dogs, polish dogs, sloppy joe's, chili, potato salad, beans, all you can eat; menu varies. Menu varies monthly, all you can eat, $5.00. Contact: Ray Bock jimgaasch@gaasch.net 989-354-5465 http://www.gaasch.net/eaa
September 10 (Mon) - Weidman MI - Pancake Breakfast, Ojibwa Airpark (D11). Fly In Breakfast. Contact: Robert Numerick rnumerick@opoa-d11.com 989-644-8084 http://www.opoa-d11.com
September 14-16 (Fri-Sun) - Terre Haute IN - Terre Haute Air Fair, Hulman Field (KHUF). http://www.airnav.com/airport/KHUF - http://www.myafd.com/airport/KHUF
September 15 (Sat) - Scottsburg IN - Annual Fly-in, Scottsburg Airport (3R8) - http://www.airnav.com/airport/3R8 - http://www.myafd.com/airport/3R8
September 21, 22 (Fri-Sat) - Mount Vernon IL - KR Annual Gathering, Mount Vernon Airport (KMVN). Annual gathering of Rand Robinson KR experimental aircraft. Contact: flesner@verizon.net Larry Flesner http://www.krgathering.org
September 21-23 (Fri-Sun) - Dayton OH - Dawn Patrol Rendezvous World War I Fly-In, Wright-Patterson Air Force Base (KFFO). Original and reproduction WWI aircraft, RC models, era automobiles and re-enactors. Contact: Sarah Swan nationalmuseum.mus@wpafb.af.mil 937-255-3286 http://www.nationalmuseum.af.mil
September 22 (Sat) - Paoli IN - Aviation Awareness Day, Paoli Municipal Airport (I42). 8 a.m. - 4 p.m. Free food an drinks for pilots flying in. paoliairport@verizon.net Contact: Bill Grefe paoliairport@verizon.net 812-723-4019 or 812-723-9923 http://www.paoliairport.homestead.com
September 27-30 (Sat-Sun) Columbus OH - Gathering of Mustang Legands, Rickenbacker International Airport (KLCK). http://www.airnav.com/airport/KLCK
October 6 (Sat) - Rockford IL - Fall Fly In Lunch, Cottonwood Airport (1C8). Chili and Barbeque Lunch, 11 a.m. - 2 p.m. Contact: Guy Stayner WNDHVR1@aol.com 815-234-4016 http://www.EAA22.org
October 7 (Sun) - Noblesville IL - EAA Chapter 67 Fall Barbecue, Noblesville Airport (I80), lunch. For more information see http://www.eaa67.org
October 14 (Sun) - Alpena MI - EAA Chapter #1021 Fly-In Lunch, Alpena County Regional Airport (APN). 10 a.m. - 2 p.m. Burgers, hot dogs, polish dogs, sloppy joe's, chili, potato salad, beans, all you can eat; menu varies. Menu varies monthly, all you can eat, $5.00. Contact: Ray Bock jimgaasch@gaasch.net 989-354-5465 http://www.gaasch.net/eaa
October 21 (Sun) - Watervliet MI - Watervliet Chili-Hop Fly-In, Watervliet Municipal Airport (40C). 11:00 a.m. - 4:00 p.m. Contact: 269-463-5532
October 27 (Sat) - Decatur IL - EAA Chapter 274 Chili Day, Decatur Airport (KDEC) - http://www.airnav.com/airport/KDEC - http://www.myafd.com/airport/KDEC - Information: 217 795 2393 - Web Site: www.decatureaa.com
Know of any other fly-ins that could be included in the fly-in circuit? Send the information to the newsletter editor at michaelandkatie@insightbb.com.
Go back to July 2007 newsletter Section 1
That fly-in time of year has arrived! If you have an aircraft and are looking for places to go, we've got some great locations and events. The following is a comprehensive list of fly-ins and other aviation events located in Indiana and adjacent states. If you don't have an aircraft but are willing to drive, the list below is round-trip "do-able" in a day. We can't guarantee that every fly-in is listed. Also, we strongly recommend that you contact the event before committing your 100LL. However, we guarantee that if you visit some of these you'll have some great fun.
September 29 (Sat) - Hanover IN - Wood, Fabric, & Tailwheels Fly-In, Lee Bottom Airport (64I). Contact: info@leebottom.com 812-866-3211 http://www.leebottom.com
Go back to July 2007 newsletter Section 2