Build log

The plane being in Essex ON near Windsor means I had to transport it about 1,100 km to get it home. A large enclosure would be required due to the delicate nature of the unassembled components and the long spar caps. I had considered renting a storage container and getting it shipped, as there are transport companies that can ensure the container remains level during loading on the truck, but there were no storage container services that serviced both Quebec and the Essex area. I thought about renting a U-Haul truck but there were none available. The loading height would also be difficult to deal with. U-Haul trailers were too small at 12′.

I found a guy renting trailers locally and he had a 16′ available with a ramp door. Perfect! I booked it for the first weekend in May, way back in February, and decided to tow it with my parents-in-law’s 2019 Mazda CX9. I would need a helper, as the seller, James, is 80 years old, so my dad volunteered to fly in that weekend.

The hitch receiver on the CX9 had never been used, and the rust had to be filed out of it, making this the first metalwork I had to do for the airplane.

We arrived about 7 am to start loading the plane, which took a little over 2 hours.

We used 480 litres of gas for the trip averaging about 21 L / 100 km at a cost of $645. Plus $460 for the trailer rental (no taxes!) plus $410 for two nights of rentals the bill for transportation was about $1500.

Next steps will be to continue cleaning up the shed and building workbenches and tables. I will also start reading the plans. The first steps on the actual airplane will be to inspect the portions already completed.

Browsing barnstormers, I found the perfect project. For longer than I can remember I wanted to own an airplane. A few years ago I decided I wanted an amateur-built due to lower total operating costs, without the restrictions of the ultra-light class. I wanted a two-seat, aerobatic, simple and convenient weekender. Anything more complex than that I could always rent.

The choices were narrowed down to a Sonex or a Zenith CH650. I had read Jeff Schultz‘ blog and seen videos of the kits, in progress and built.

A popular, time-tested airframe from an existing company would ensure good support during the build, as I could learn from past experiences building similar aircraft. A kit would save time and probably some cost too. The motors were smaller and from lesser-known companies, but Continental and Lycoming motors are just too expensive. A Van’s would be nice, but prices have skyrocketed and it did not seem to be more cost-effective to build vs. purchasing a certified aircraft.

On Barnstomers, someone was selling an unfinished Sonex kit and Jabiru 3300. I wanted the Jabiru, which is significantly more powerful than the standard VW engine of the Sonex, and allows for a large weight increase. The seller was in Canada, so I would not have to bother with importing anything, and he seemed nice on the phone. With the encouragement of Molie I made an offer without even seeing it. $14,000 beaverbux seemed like a great deal; new Sonex-B kits start at a base price of $50k, without tax, transport, or engine!

I will be picking up Sonex #1279 on the weekend of May 4. Located near Windsor, ON, James Neely bought this kit, also unfinished, with the intention of building his second Sonex. His first Sonex was plans-built and took 11 years to complete. I hope I can finish mine in a little less time.