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Not sure if an aircraft construction project is right for your school? Run a short pilot program with your students using the Sonex Education Starter Pack, a scalable metalworking project and curriculum guide.
This fun and interesting metalworking project is the actual assembly constructed by prospective Sonex Aircraft builders at Sonex Builder Workshops held several times annually at our factory in Oshkosh, WI. It is designed to teach the basic metalworking skills required to build our line of aircraft, which offer the Best Performance Per Dollar in the kit aircraft marketplace. This project and its documentation have been refined via use by hundreds of Sonex Workshop attendees and it is ideally suited to provide youth with an introductory exposure to aircraft construction.
Starter Pack Features
The Sonex Education Starter Pack includes instructional material, plans and materials to construct the Sonex Workshop metalworking project. A Teacher’s Guide is provided to step teachers through acquiring and fabricating the materials and tools required to prepare the shop for this project, along with suggested grading points for student projects. A 22 page Student Guide is included for duplication to become each student’s text for this project. A Sonex Drawing System Features chart is provided for posting in your class as a guide to using Sonex plans and as a teaching aid for classes involved in mechanical drafting projects. A Sonex Aircraft, LLC Complete Info Pack, including 3 DVD videos, and Sonex, Waiex and Xenos 3-View Drawings are provided for posting and exhibition in your class in order to inspire and motivate students and teachers alike with the fun and excitement of sport flying. So long as it does not negatively impact shop safety, this is one class in which we feel that daydreaming is required for success! Helping others work toward the fulfillment of their dreams is our business here at Sonex, and we believe in the power of a student’s dreams to guarantee success in their future.
Complimentary Curriculum
The Sonex Education Starter Pack is not intended as an all-inclusive course curriculum, but rather a catalyst for inspired learning. We highly encourage teachers to use this project as a hands-on tool to compliment other aviation-related curriculum, or as a way to make an aviation-related link to required school curricula. Links to other complimentary aviation curricula that you may find useful for your class are available on the Resources page of this web site.
Required Teacher Qualifications
Although this starter pack includes instructional reference material, a prior knowledge of metal aircraft construction techniques is required to effectively teach this project to students. We encourage all teachers to strongly consider attendance of a Sonex Builder Workshop in Oshkosh, WI to become fully familiarized with our product line and Sonex-specific construction techniques. Additionally, you may use the Sonex Builder Database to find Sonex builders in your area or ask for help from your local chapter of the Experimental Aircraft Association (EAA).
Availability
Sonex Education Starter Packs are only available to Accredited Educational Institutions and Community Organizations for youth education. These Starter Packs are not intended for adult education to those who may be seriously considering a Sonex Aircraft, as the Sonex Builder Workshops in Oshkosh, WI will give those individuals a much more in-depth and specific workshop experience that covers many more aspects of building, owning and operating Sonex Aircraft than the Sonex Education Starter Pack metalworking project alone.
Scaled Starter Pack Options
The Sonex Education Starter Pack is available in the following 3 class sizes. To order additional materials individually, simply follow the link on each item, where available.
16 Student
Starter Pack |
30 Student
Starter Pack |
50 Student
Starter Pack |
16 Student Starter Pack includes:
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Price: $300
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30 Student Starter Pack includes:
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Price: $450
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50 Student Starter Pack includes:
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Price: $700
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| Additional Items Needed: Each class must source the following addtional materials from aviation material suppliers such as Wicks Aircraft Supply.* A few miscellaneous items needed for classroom tooling detailed in the Teacher's Guide must also be sourced from your local hardware store. |
16 Student Starter Pack requires:
Aluminum Sheet Stock:**
Or:
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30 Student Starter Pack requires:
Aluminum Sheet Stock:**
Or:
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50 Student Starter Pack requires:
Aluminum Sheet Stock:**
Or:
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*Links to Wicks Aircraft Supply items above are for reference only and are subject to change. Always default to published part numbers or specifications above to order.
**Your choice of aluminum sheet stock above may depend on shipping cost of 2' x 4' sheet vs. 4' x 12' sheet. Qty recommendations above include extra material for mistakes. Each 4' x 12' sheet provides enough material for Qty 18 projects. Qty 2 sheets of 2' x 4' stock is required to make Qty 5 projects. |
| Tools Required to Construct the Sonex Education Starter Pack* |
| Description |
Source and
Part Number |
Quantity Required |
| Band Saw, wood cutting, 5-6 TPI blade (table model is ok) |
Any Local Hardware Store |
1 or more per class |
| Drill Press, Small (table model is ok) |
Any Local Hardware Store |
1 or more per class |
| Fly Cutter adjustable up to 4” hole |
Any Local Hardware Store |
1 per drill press |
| Hand "Pop" Rivet Tool (Qty 1 or more per class) |
Any Local Hardware Store |
1 or more per class |
| Sledge Hammer for bucking rivets: 2 lb, short-handled |
Any Local Hardware Store |
1 per Bucking Bar |
| 3/8 Reversible Drill (cordless is ok) |
Any Local Hardware Store |
1 per student, or rationed among students |
| 1/4” Drill Bit |
Any Local Hardware Store |
1 per 3/8 Reversible Drill |
| #40 Drill Bit |
Any Local Hardware Store |
1 per 3/8 Reversible Drill |
| #30 Drill Bit |
Any Local Hardware Store |
1 per 3/8 Reversible Drill |
| #21 Drill Bit |
Any Local Hardware Store |
1 per 3/8 Reversible Drill |
| Steel Ruler: 12” Ruler-32nds + 64ths |
Any Local Hardware Store |
1 per student |
| File: 8" half-round fine-tooth |
Any Local Hardware Store |
1 per student, or rationed among students |
| Sandpaper: 220 to 400 grit wet-sanding paper (use dry only) |
Any Local Hardware Store |
1 per student, or rationed among students |
| Safety Goggles |
Any Local Hardware Store |
1 per student or instructor |
| Sharpie Markers-Blue Fine Point |
Any Local Office Supply Store |
1 per student |
| Plastic Mallet |
Sears Craftsman P/N 38292 |
1 per SNX-FB-07 Fwd Rib Form Block |
| Cleco Pliers |
Wicks Aircraft Supply PN: 200-SHP |
1 per student, or rationed among students |
| Clecos, 3/32” |
Wicks Aircraft Supply PN: AT551X |
25 per student |
| Clecos, 1/8” |
Wicks Aircraft Supply PN: AT552X |
25 per student |
| Clecos, 5/32" |
Wicks Aircraft Supply PN: AT553X |
8 per student |
| Andy Aluminum Snips |
Wicks Aircraft Supply PN: MC14 |
1 per student, or rationed among students |
| C-Clamps with Swivel Pads |
Wicks Aircraft Supply PN: 6CLAMP |
2 per student, or rationed among students |
| Vixen File |
Wicks Aircraft Supply PN: VX10 |
1 or more per class |
| Fluting Pliers |
Avery Tools PN: 500 |
1 per student, or rationed among students |
| Deburring Tool |
Avery Tools PN: 1046 |
1 per student, or rationed among students |
| Optional Tools |
| Pneumatic “Pop” Riveter |
Harbor Freight Tools PN: 93458-6VGA |
1 or more per class |
| Compressor, Small (if using pneumatic “Pop” riveter) |
Any Local Hardware Store |
1 per class |
| 3M Scotch Brite Wheel |
Wicks Aircraft Supply PN: F3753 |
1 per bench grinder |
| Bench Grinder (if using Scotch Brite Wheel for deburring/finishing) |
Any Local Hardware Store |
1 or more per class |
*Note: where Qty’s given in a range per student, use your own discretion in rationing Qty’s among students per your class size and budget constraints.
Links to supplier part number items above are for reference only and are subject to change. Always default to published part numbers or specifications above to order. |
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