Time:
5 hours (sub-assemblies),
5.5 hours (counterweights)
Date Complete: Feb 20, 2023
Building the Sonex's aileron counterweights and sub-assemblies was mostly straightforward, apart from a broken drill bit that got stuck in a lead block. The key to machining lead correctly is the liberal use of cutting oil whenever cutting or drilling. Lead is very soft and has a low melting temperature. The cutting oil reduces friction and dissipates head. It also acts as a block to ensure the lead doesn't adhere to your cutting tool (saw blade, drill bit, etc.)
Here's a video detailing how I completed the counterweight assemblies, but you can also see the sub-assemblies in the thumbnail image for the video: