SonexFlight is a monthly podcast where we talk all things related to the Sonex line of kit-build aircraft. Each show we interview a different Sonex builder or pilot and discuss technical topics, tips and tricks, flying adventures, news and current events.



As 2017 wraps up, the cast of SonexFlight is seeking your feedback on the podcast. We're looking for your input on how often you listen to the show and what method you use to listen, what topics you like and what topics you want more of, or anything you'd suggest we re-look or adjust. Most of all we want to know if we're hitting the mark, so log onto our survey and tell us.

The survey is quick and easy, and only takes a couple minutes to complete. There are plenty of opportunities for comments, so be as detailed as you want. The survey will be open thru December 2017, and we'll report the results early in 2018.

Thank you for your feedback and your insights!

Take the Survey!


Episode 31 - “Prince Propellers"

Regardless of engine choice on your Sonex you’re going to need a prop to go with it. There are many choices, but the goal is the same – to get an efficient, durable, good looking prop for a reasonable price. Prince Aircraft Company is one of the best respected propeller brands available for the Sonex. Lonnie Prince tells us about his prop and how to create speed out of thin air.

Download Episode 31 (mp3)


Episode 30 - “Flying the JSX-2 SubSonex Jet"

(AKA "SubSonex by a Regular Guy!”)

Every pilot dreams of flying their own jet, especially one that is small, fast and maneuverable. Sonex Aircraft has fulfilled that dream for a handful of customers, but there’s much more potential for others to join the ranks as well! John Corneal is an early SubSonex builder and talks about how a “regular guy” was able to pull this off.

Download Episode 30 (mp3)


Episode 29 - “Annual Condition Inspection"

Fall is here, and for many people that means flying is slowing down and it’s time to conduct the annual condition inspection. We’ll review the areas typically inspected during a good condition inspection, and go over our best practices for Sonex-specific items that should be on your checklist.

Download Episode 29 (mp3)


Episode 28 - “2017 Reklaw Fly-in"

"Camp Sonex" was formed once again, this time at the 31st Annual Fly-in at the Flying-M Ranch in Reklaw, TX! This gathering is a special event, and it's hard to describe why it's so loved by those who attend. The cast and attendees attempt to put the magic of Reklaw into words as we catch up around the camp fire.

Download Episode 28 (mp3)


Episode 27 - “Sonex Handling Qualities”

Captain Mike "Caveman" Neidenthal joins us again as we attempt to describe the feel and personality of flying a Sonex, and to give some insight to why Sonex has such a loyal following of pilots. Simply put, we love the way they fly, and we’re going to tell you all about it!

Download Episode 27 (mp3)


Episode 26 - “Vacuum Bending Leading Edge Skins”

We discuss an alternate way to bend the leading edge skins using an ordinary shop vac, rather than the complicated process of press-bending the skins. The vacuum bending technique is great for scratch-builders, or for those kit builders that have to replace their leading edge skins and want to avoid the cost of buying (and shipping) pre-fabricated skins from the factory.

Download Episode 26 (mp3)


Episode 25 - “Alaska by Sonex”

Waiex builder Jim Hicke is back from his 3-week Alaska trip. This was an epic trip, filled with spectacular sights and video, unexpected rewards, and a few unpleasant surprises. We discuss Jim's highlights and his challenges, the planning involved, and lessons learned from making a big trip in a Sonex.

Download Episode 25 (mp3)


Episode 24 - “Taking the Plunge and Becoming a Builder”

The process of moving from Interested Outsider to Full-fledged Builder can be intimidating as the would-be-builder conducts research, builds support for the project, and works up his or her budget. Our guest this episode did just that and recently took the plunge into building.

Download Episode 24 (mp3)


Episode 23b - “Oshkosh Wrap-up”

AirVenture 2017 is over, and it was a great show! The SonexFlight crew is back home, and we review the remainder of the show and reminisce on the interesting things we experienced.

Download Episode 23b (mp3)


Episode 23a - “Oshkosh 2017 - Camp Sonex!”

AirVenture 2017 is under way, and 'Camp Sonex' is officially open! We report on the first couple days of the show, tell what we've seen, and what we're looking forward to seeing and doing. Oshkosh is off to a great start.

Download Episode 23a (mp3)


Episode 22 - “Preparing for the Unexpected”

Preparing for unexpected situations starts before you even leave home. We discuss the prep that we conduct before venturing out of the local flying area, the tools and supplies that accompany us, and how the right mindset allows you to enjoy the adventure of the trip rather than focusing on the difficulties.

Download Episode 22 (mp3)


Episode 21 - “Electrical Systems, Part 2”

Bob Nuckolls is back, and we continue our discussion of electrical systems, including topics such as regulators, sources of electrical noise, and grounding practices.

Download Episode 21 (mp3)


Episode 20 - “Electrical Systems”

We scratch the surface of practices and considerations behind designing and implementing the electrical system for your Sonex project. We’ll speak with a well-respected and recognized expert in aircraft electrical system design, Bob Nuckolls, and tap into his more-than-50 years of experience.

Download Episode 20 (mp3)


Episode 19 - “Cross Country via Sonex”

This episode we discuss the process of making longer flights via Sonex. Famed Sonex pilot Kip Laurie talks about his cross-country flying process, and how he gets the most out of his Waiex for travel.

Download Episode 19 (mp3)


Episode 18 - “Aux Fuel Systems”

One comment often heard from pilots is the desire for more range or endurance. This month we’ll look at a few custom solutions that have been created by builders to provide more fuel capacity, and highlight a few items to consider to start you on the right track when developing your own system.

Download Episode 18 (mp3)


Episode 17 - “Reducing Sonex Accidents”

We tackle a really tough problem – how to reduce the frequency and severity of accidents among Sonex pilots. Our discussion approaches the topic through a Sonex-specific lens, but certainly applies to all aspects of aviation.

Download Episode 17 (mp3)


Episode 16 - “Autopilots”

We explore the situations where a builder may consider installing an autopilot is a Sonex project, even though the Sonex is thought of as a rather "sporty" airplane. We’ll dig in to the details of the popular autopilot offering from Dynon Avionics.

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Episode 15 - “Sonex Acro”

We explore the ins and outs of flying aerobatic maneuvers in a Sonex, review the types of maneuvers appropriate for a Sonex, and go over a few tips from our guest Mark Kingman to make flying acro a bit easier. In the news we discuss the NTSB's recently released Factual Report of the 2014 Sonex crash near Big Bear, CA.

Download Episode 15 (mp3)


Episode 14 - “Brakes”

We discuss the various options and consideration for choosing brakes for your Sonex project, including the stock drum brakes, optional AeroConversions hydraulic brakes, and other aftermarket brake systems. Guest Mike Farley offers his experience and insights gained from his project. In the news we discuss the first look at Jabiru's new "Generation 4" engine.

Download Episode 14 (mp3)


Episode 12 - “Rivets”

We delve into all aspects of rivets on the Sonex. We’ll discuss the types of rivets used in our construction methods, proper techniques, tools and various tips and tricks learned over the years.

Download Episode 12 (mp3)


Episode 11 - “Developing a Pilot Operating Handbook”

We discuss the process of putting together a Pilot Operating Handbook – AKA a “POH”. We review the major considerations and a few helpful references to guide you through the development a complete and useful document. We also comment on our own individual methods of operating our Sonex, from start-up to flying the pattern.

Download Episode 11 (mp3)


Episode 10 - "Documenting Your Project"

We discuss documenting your Sonex building project, including the regulatory requirements for documentation, the various options for your logs, benefits of documenting, and tips and tricks to make the process easier. In the forum news we review the pro's and con's of delaying riveting the lower fuselage skins, and discuss ways to fix elevator bellcrank interference in the tail.

Download Episode 10 (mp3)


Episode 9 - "Landing Gear"

The Sonex landing gear system is robust, effective and simple to set up, and we cover ways to make it even easier. We talk with early plans-builder Bob Mika about planning considerations for your gear configuration, challenges or issues builders may encounter, tips and tricks, and a few useful modifications.

Download Episode 9 (mp3)


Episode 8 - "Rescuing an Orphaned Project"

We discuss the advantages and disadvantages of purchasing a second-hand Sonex project, outline the major considerations on finding and evaluating a potential project, and offer tips and lessons-learned from builders who have successfully completed rescued projects.

Download Episode 8 (mp3)


Episode 7 - "Tuning the AeroInjector"

We discuss tuning the AeroInector and AeroCarb. This carb is deceptively simple, but it needs to be tuned correctly for best performance. Kerry Fores from Sonex Aircraft LLC walks us thru the process, outlines common mistakes and provides trouble-shooting tips.

Download Episode 7 (mp3)


Episode 6 - "Talking with Sonex, LLC"

In Episode 6 we speak with Sonex Aircraft LLC General Manager, Mark Schaible. We discuss a wide variety of topics with Sonex, review the latest efforts and focus areas, and talk about Sonex’s biggest challenges and frustrations. In the news we review the UK Sonex Approval Document, the recent AeroVee Turbo Service Bulletin, and more.

Download Episode 6 (mp3)


Episode 5 - "Sonex Builders and Pilots Foundation"

In Episode 5 we speak with Robbie Culver, President of the Sonex Builders and Pilots Foundation. We talk about the mission and goals of the Foundation, transition training and other safety concerns. In the news we discuss recent threads about solving radio noise, and the Stratux do-it-yourself ADS-B receiver.

Download Episode 5 (mp3)


Episode 4 - "Engine Cooling"

In Episode 4 we discuss important considerations to achieve good engine cooling in your Sonex. We speak with Mike Smith about his recent experiences trouble shooting and improving his engine cooling efficiency. In the news we discuss a recent Sonex forced-landing, thankfully with only minor injuries, Josh Bardell's homebuilt portable air-conditioning system for his Sonex, and more.

Download Episode 4 (mp3)


Episode 3 - "AeroVee Turbo"

In Episode 3 we discuss the AeroVee Turbo engine option for the Sonex. We speak with Mike Farley and Carl Benda, two highly-experienced Turbo owners, detailing the Turbo package itself, the modifications to your Sonex to add a Turbo to an already-flying AeroVee-powered Sonex, and performance of the Turbo (Spoiler - it Rocks!). We also review current news, Forum discussions and more.

Download Episode 3 (mp3)


Episode 2 - "Fuel Systems"

In Episode 2 we hold a round table discussion regarding fuel systems. We review what the plans call for, important considerations in designing your own fuel system, common modifications, and mistakes or pitfalls that frustrate builders. We also review recent Sonex new product press releases and recent forum topics.

Download Episode 2 (mp3)


Episode 1 - "Why a Sonex?"

In this episode we speak with a current Sonex builder and discuss his project, and find out why he chose the Sonex. In the forum news we discuss our favorite plans features and mods, discuss the Factory Waiex crash near Fond du Lac airport and the NTSB report on the Tom Huebbe fatal accident in 2014.

Download Episode 1 (mp3)




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