...ready for final assembly (June 7th 00)

Oh, boy, I like this cute little filler box. OK, OK, this is not an airplane, it's just a FILLER BOX, but it's mine and it's completely homemade :)))

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...Weekend's production (June 3rd-4th. 00)

These are most of the stainless steel parts used for the firewall. I heared a lot of bad things about working with stainless, but actually it was easier than expected. For all the pilot holes I used only one drill bit (the good US cobalt drill bits from Avery Tools), and it's still sharp. On every center punch I put a small drop of WD-40 which evaporated while drilling. The drill was set to low speed (approx. 500 rpm). Even the flange bending business seems to be under control now.

...still waiting for the big box (June 2nd, 00)

The wingrib gussets consumed my last reserves of 2024-T3. This alloy is about 30% stronger than the 6061-T6 however it's also twice as expensive. So if you like to build a Sonex-Rolls Royce use this stuff :))

The ordered 6061-T6 has still not arrived. So I'll continue with the stainless firewall. The 301 material I bought at a dealer nearby (however 0.5mm instead of the required 0.4mm per the plans). Rough cutout using my roller shears was easy. I cut about 2 to 3mm wider and then filed to the exact measurements using a body file? (German: Karosseriefeile). This file is very effective. You need only a few strokes to remove the 2-3mm of excess stainless (it's 39 degC / 84deg F, rapid body movement will let flow the sweat).

...finally (June 1st 00)

the wingrib gussets are completed 48 pieces altogether (I'll install 2 additional wingribs at each side). Touching this polished and nicely rounded pieces is a sensuous experience ;)))