Sonerai 1 - Suitable for a first build?

[bobthebuilder]

Is a Sonerai 1 suitable as a first build?
Are any special tools and skills required?

[Kevin]

Where are you located?? I am curious reference your seeking an LSA etc.

Thanks,
Kevin

[raceair]

I would say a Sonerai 1 is suitable, providing you know how to gas weld, or plan on learning. I do not recomment MIG welding on tubular structures....I would Gas or TIG weld the airframe. The wing goes together well, although you will have to either get riveting equipment for the spar assembly, or go with the modified hand arbor press to squeeze spar rivets.
The canopy requires patience, so as to not crack it while trimming or fitting. ......Ed F.

[bobthebuilder]

Hi Kevin,

I am in Johannesburg, South Africa.

We have slightly different rules regarding LSA over here:

Max take off mass: 600 kg for land plane
Maximum Stall Speed at Gross Landing Configuration: 45kts
Maximum speed, level flight max cont power: 150 kts
Max no seats (incl Pilot): 2
Single engine (non turbine or jet): yes
Unpressurised: yes
Prop: Fixed or VP or CS in flight adjustable
Undercarriage: Fixed tricycle or tail wheel or retract

[bobthebuilder]

Hi Ed,

Is the rivet press only needed for the spar? We have one at work.

Here in South Africa, I think we can only tack the frame together. Thereafter we have to have a certified aircraft welded finish it up. I will check with the boys at our local EAA meeting next week.

The canopy for the S1 is not supplied by Great Plains. What have other builders used?

[wbpace]

Special skills? No. Lot's of new skills? Depends on the person, but almost certainly. But that is why most of us build in the first place, to learn new things.

There is nothing about building an airplane that requires more than average intelligence, patience (lots!), a willingness to learn, and (very important) a connection to the builder community to help you make wise decisions. If you have not yet joined EAA and your local EAA chapter, do so now.

Accept that you will make mistakes, and some will cost money to correct. That's part of the learning experience. You will probably have to buy at least a few new tools and learn to use them - but that for most of us guys, that is like offering candy to a child ;-). Wise money spent on optional tools often translates to quicker build times. But you get to make the time vs. cost tradeoff.

Go to the EAA website and start looking through the Hints for Homebuilders. There's a wealth short videos with information, training, shortcuts, money saving ideas, etc. there. Again, your local chapter can point you to resources, help, or even be willing to show you how to do things.

For my part, I have to learn welding to build my Sonerai. I have never spent more than 5 minutes behind a torch at Oshkosh Airventure about 15 years ago. Intimidating? A bit. Showstopper? Never! Learning to weld was one of the reasons I picked the Sonerai. I learned riveting years ago when I started a (since abandoned, I can go into that another time) RV-6A project. I taught myself how to rivet using videos/books, and will probably do the same with welding (with some backup from my chapter). (Sidebar: I pulled out my old RV kit a few months ago (boxed up for over 10 years), and I have to say it looked like d**n good work! And that is with all driven rivets, not the pop-rivet stuff used with Sonerai's. If you are your own harshest critic, you will do at least as well.)

Finally, realize up front that this will likely take a lot longer than you think. Set short term goals and enjoy them as you meet them, or you will quickly become frustrated. There's an old saying that if you want to build, then build - if you want to fly, then fly. If your major motivation is you just want a cheap ride, go buy an old (but good) 1940's or '50's airplane and fly. If you enjoy building, then build - but for most people the latter means there won't be any funds to fly for possibly years to come. As for me, I fall into both camps - I wanna fly, but I can't afford to. I want to build, but it will be slow going due to money and time constraints. At the end of a long road, I can start flying again. I have to take a long view. YMMV.

Good luck with your decision. If you do chose the Sonerai, you will find that this is one of the most helpful communities out there.

Bill

[bobthebuilder]

Thanks for your insight Bill..... true words of wisdom!

EAA. - I am not a member as of yet, but have made arrangements to attend the next meeting which will be held next Saturday.

My choice of aircraft project doesn't seem to please the more experienced aviation experts at our local club.
There are many kit and scratch build options available. What appeals to one person, may not appeal to all.
Single seaters for example are frowned upon by our club folks. The general consensus is that single seaters are selfish airplanes, that do not hold their value, and are difficult to sell when the time comes.
Now all of these facts may be true ..... But I still want a single seater!

The engine in the Sonerai is another topic of hot debate. The reliability of the VW platform has been questioned. Some say it is reliable, others suggest that it is only reliable as a boat anchor, and that the Jabiru 2200 is a far better option.

Put these two arguments together, and Sonerai 1 is not the preferred project by our panel of experts....... But I still want one!

Time to change clubs I guess?

[raceair]

Remember, you will be the builder, not the committee that is giving you advice back home. For me, I would not consider anything but a VW on a Sonerai....It is still the most bang for the buck.....Every other engine choice is either heavier, or costlier.......or both.......'Most' of the Anti-VW engine people around here, at least, have never flown one....But they are experts at giving advice. John designed this airplane for VW power.
The spars have driven rivets, the ribs are attached to the shear webs with Monel style pulled rivets...'pop rivets', 'avex rivets', they are called many things. The wing skins are attached with pulled rivets as well. Almost all Sonerai 1's use dimpled skins, and flush rivets, but I have seen a couple with protruding head rivets.
In the end, do what You want to do.....most of the anti- single seat people need to look at their logbooks, over their 10, 20 or 30 year flying career, and look at how many hours they logged solo. If you want to take a passenger to a fly-in, go rent a 2 or 4 seater....Ed

[bobthebuilder]

Hi Ed,

I can tell you that apart from some dual for license renewels with an instructor, I have flown PIC with a passenger 5 times in five years. An average of once a year.
A single seat aircraft is perfect for me. I absolutely love the mid wing configuration of the S1, coupled with the cowl that flows into the wing. The shoestring lines .... Beautiful! ..... I want one.

As for the engine, I feel the same way about the VW. The aircraft was designed for it.
In terms of quality and reliability, is it safe to purchase from Great plains?
What is the recommended engine size, the original 1600, or bigger?
Unfortunately, it cannot be raced over here, we don't have air racing over here. There are therefore no rules to comply with in that department.

[heisan]

Hi Bob,

Which chapter are you joining? The Spence family at 973 (Krugersdorp) has a very nice, nearly complete S1, which is nice to drool over. Lots of good info/help available from them too.

I am hunting for a S2LS to bring in from the USA. If I ever find one, I will be bringing in a container. Could probably fit an S1 (or the parts to make one) into the container too, if you are interested.

Justin

PS: If you want to race, there is always the Unlimited Challenge Air Race - you can eat the KRs for breakfast on the 500km closed course...

[bobthebuilder]

Hi Justin,

I am not sure of the chapter number. It is the east rand guys that meet at Springs airfield.

Do you perhaps have contact details for the member of the Spense family who is building the S1?

I would be interested in sharing container space if the time lines correspond. Thanks for the offer.

[heisan]

Sent details via PM.

Justin

[raceair]

Bob...Yes, Great Plains aircraft has a very nice engine kit ....Its almost one stop shopping, because they also have the authorized component parts for the Sonerai line.
As well, From time to time, a partially built project comes up, reasonably priced.
You get very useful performance with the 1600 engine, and I recommend that for general fun, but as many people have done, the bigger displacement engines really up the performance, for not that much more $$$....You can always build it with a 1600, then later upgrade to an 1834, or larger. The 2180 really makes the Sonerai 1 Scream.......Ed

[bobthebuilder]

Thanks Justin.