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Rights Reserved. The information

disclosed herein is the property of

the originator who reserves all pat-

ent, design, proprietary, manufac-

turing, use and sales rights thereto,

except for the rights expressly

granted to others. This document

shall not be reproduced nor shall

the information contained within

be used by or disclosed to others

except as expressly authorized by

the originator.

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Oshkosh, WI 54903

Phone (920) 231-8297

fax (920) 426-8333

email:info@sonexaircraft.com

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 signicant

errors or omissions, please bring them to our at-

tention.

Note: The following materials are not included

in this list. Hardware (rivets, ttings, 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

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

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

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.

Summary of content (6 pages)

PAGE 1
MATERIAL PLANNING GUIDE About this Guide... This guide has been developed to help you minimize 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.
PAGE 2
MATERIAL PLANNING GUIDE (cont.) Sheet aluminum layout... The following illustrations depict a material-efficient pattern for cutting the parts out of the aluminum sheets. The bold outlines filled with gray represent the individual sheets of aluminum. The size of each sheet of aluminum is identified above each illustration. The thin outlines filled with white represent the individual parts of the Sonex. The parts are identified in one of two ways: by Sonex part number or by description.
PAGE 3
MATERIAL PLANNING GUIDE (cont.) .025 6061-T6 aluminum sheet, 4’ x 12’ SNX-B07.9 Material Planning Guide Page 3 of 6 rev. n/c .025 6061-T6 aluminum sheet, 4’ x 12’ .025 6061-T6 aluminum sheet, 4’ x 12’ .025 6061-T6 aluminum sheet, 4’ x 12’ © 2012 Sonex Aircraft LLC. All Rights Reserved. The information disclosed herein is the property of the originator who reserves all patent, design, proprietary, manufacturing, use and sales rights thereto, except for the rights expressly granted to others.
PAGE 4
MATERIAL PLANNING GUIDE (cont.) .025 6061-T6 aluminum sheet, 4’ x 12’ SNX-B07.9 Material Planning Guide Page 4 of 6 rev. n/c .025 6061-T6 aluminum sheet, 4’ x 12’ .025 6061-T6 aluminum sheet, 4’ x 12’ .025 6061-T6 aluminum sheet, 4’ x 12’ © 2012 Sonex Aircraft LLC. All Rights Reserved. The information disclosed herein is the property of the originator who reserves all patent, design, proprietary, manufacturing, use and sales rights thereto, except for the rights expressly granted to others.
PAGE 5
MATERIAL PLANNING GUIDE (cont.) SNX-B07.9 Material Planning Guide .032 6061-T6 aluminum sheet, 4’ x 12’ Page 5 of 6 rev. n/c .032 6061-T6 aluminum sheet, 4’ x 12’ .032 6061-T6 aluminum sheet, 4’ x 6’ .090 6061-T6 aluminum, 2’ x 4’ .125 6061-T6 aluminum, 2’ x 4’ © 2012 Sonex Aircraft LLC. All Rights Reserved.
PAGE 6
MATERIAL PLANNING GUIDE (cont.) Aluminum Angle Layout... Building the Sonex requires a number of different sizes of aluminum angle. As most sizes are needed in such small quantities that only a single length of each size needs to be ordered, using this material efficiently is not a problem. However, the .125 x 1” x 1” aluminum angle is required in greater quantity. To help you get the most parts from the least amount of material we suggest the following cut list be followed. Cut List for the .