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How we Built our Onex
Volume 2

A step by step video demonstration for builders of the popular Onex light-sport aircraft kit from Sonex

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This 2 part video (originally sold as a double DVD set) continues the building sequence from where Volume 1 ends. (The demonstration of building shown in this video requires the viewer to have watched Volume 1 in its entirety.  This video is not meant to be useful without first watching Volume 1)  Volume 3 info can be found by clicking here.

The pictures on this page are captured from the video itself and provide a look at the scope of building that is covered in this volume.

Note: This production is not associated or endorsed by SONEX. It does not replace or supersede the documentation provided with the kit.  It is meant to be an aid in building the aircraft and its methods are presented only as a suggestion to builders.

This video set  is approximately 2.5 hours in length .

 
                                   Inserting Main spar                                                                 Assembling spar brackets

 
                     Assembling Spar plate                                                                        Attaching Spar to Fuselage

 
                                    Drilling spar support                                                                               Rudder Pedal Setup

  
                                  Seat installation                                                                                         Rudder pedal mounting

 
                             Brake/Flap handle detail                                                                          Brake pivot detail

                          Engine mount install                                                                                  Rear Spar components

                         Fitting Glare shield                                                                              Fitting Windshield

                     Creating template for Canopy frame                                                     Forming Canopy frame bow

                         Completed Canopy frame                                                                  Corners detail

                              Trial fit bubble                                                                               Taping for Cut line

All photos on this page are screen shots from the Volume 2 video

Mounting the main gear
 

Using a right angle drill for cross support bolts
 

Brake and axle assembly completed
 

Assembling Spar end parts

Cable pulley bracket fabrication

Bushing install for stick pivot



Stick installation
 

Flap handle mechanism
 

Firewall cable pulleys
 

Trial fitting Fuel Tank

Cutting Windshield

Trial fit Panel

Canopy Cutting tools used

Cutting bubble