SonexBuilders.net

You know you're a workshop addict when your wet/dry sandpaper order is over $100....

Bob Dz, builder of a rare wooden Sonex. Hope you go with stain and the natural grain look rather than paint.

Bryan Cotton wrote:Bob Dz, builder of a rare wooden Sonex. Hope you go with stain and the natural grain look rather than paint.

I'm thinking black walnut for the panel....

Ironwood Brake Handle

Nice Bill!

Very nice Bill!

All I need to know is how did you get the rectangular hole up the middle of the handle? .

Area 51% wrote:All I need to know is how did you get the rectangular hole up the middle of the handle? .

I've been wondering that too. Immediately started thinking "how would I do that". First thing that came to mind was a two piece design with a routed rectangular slot, then glue the two pieces together.

Another option, commonly used to put square tanged files into a wood handle, is to burn it in. Drill a round hole into the handle, then take a similar sized piece of steel, heat it red hot, and burn it into the hole. I often use this method when I make tools.

Sorry for the slow response - been in the hangar today working on my B Model Upper Cowl Mod.

Bob was correct - it was a two piece design with a routed rectangular slot, then glued the two pieces together with J-B Weld. I also drilled a couple of holes in the aluminum to make sure the epoxy captured the aluminum handle. Quite sure it will never come off.