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601xl spar insert

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K Dilks

Joined: 22 Sep 2008
Posts: 108
Location: UK

Posted: Sun Aug 09, 2009 3:35 am Post subject: 601xl spar insert

Hello,

Its Sunday and I am stuck/ confused.

I understand i need to make a wing jig from plywood , but can anyone explain about the part mentioned in the photo guide called the spar insert. Is this supposed to come from ZAC ready made or am i supposed to make it?



The confusion is that they call it wing jig 6-B-13 but this is the wing uprights on the shipping list.

  I cant find the insert nor material to make it from!

 Building from a full kit.

Thanks for any help, bit urgent as now my day has stopped!

Thanks

Kev

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_________________
Back home .................

Iberplanes

Joined: 10 Dec 2007
Posts: 174
Location: Igualada - Barcelona - Spain

Posted: Sun Aug 09, 2009 4:12 am Post subject: 601xl spar insert

Well Kev, 



We are synchronized !  I´ve sent an email today to ZAC asking the same thing !!! I´ll let you know as soon as I get news from them.



Bye ! 



Alberto Martin

www.iberplanes.es

 Igualada - Barcelona - Spain



----------------------------------------------

Zodiac 601 XL Builder

Serial: 6-7011



Tail Kit: Finished

Wings: Not Started

Fuselage: Started

Engine: Jabiru 3300

   [quote][b]

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_________________
Alberto Martin
601 XL - Jabiru 3300
http://www.iberplanes.es
Igualada - Barcelona - Spain

psm(at)att.net
Guest

Posted: Sun Aug 09, 2009 5:19 am Post subject: 601xl spar insert

Hi Kev,



The parts for the wing jigs came with my XL kit.  I don't remember 

which sub-kit they were in, but I suspect it was the fuselage.  At 

that time there was no wood in the wing jigs at all, but I don't see 

why the main piece couldn't be plywood rather than heavy aluminum as 

was included in my kit.



The spar piece is a rough copy of the end of the main wing spar that 

must be inserted in the fuselage spar carry-through.  It needs to 

have the same general shape and thickness as the real wing spar, but 

it doesn't need to be particularly nice or strong.  If you made your 

own wing spars and included an extra 8 inches or so of length then 

cut off the extra length this would be a good piece to use for the 

jig.  (If you are as unfortunate as I am and scrapped one of your 

wings then a piece of the scrapped spar would be fine too.)



The wing jig is a mock up of the finished wing to fuselage mating 

features.  It is used to get the spar carry through and the rear 

channel mating tab in the right place on the fuselage side to mate 

with YOUR wing.  You need two - one for each side of the fuselage.



Good luck,



Paul

XL waiting for engineering changes





At 04:35 AM 8/9/2009, you wrote:

 	  Quote: 	
		  Hello,

Its Sunday and I am stuck/ confused.

I understand i need to make a wing jig from plywood , but can anyone 

explain about the part mentioned in the photo guide called the spar 

insert. Is this supposed to come from ZAC ready made or am i 

supposed to make it?

   I cant find the insert nor material to make it from!

  Building from a full kit.



Thanks for any help, bit urgent as now my day has stopped!

Thanks

Kev

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vk3eka(at)bigpond.net.au
Guest

Posted: Sun Aug 09, 2009 5:36 am Post subject: 601xl spar insert

Paul/Kev,



My kit was new last September and didn't come with the wing jig parts. The

reasoning was that with all the pre drilled holes I didn't need one. I

borrowed a set from another builder and had not problems fitting it to the

fuse after matching the predrilled holes etc (i.e. good to have for peace of

mind but not necessary).



Cheers



Peter

Wonthaggi Australia

http://zodiac.cpc-world.com



--

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jaybannist(at)cs.com
Guest

Posted: Sun Aug 09, 2009 5:36 am Post subject: 601xl spar insert

Kev,

 

 If you are talking about the spar center section jigs, I received all the parts to make them with my fuselage component kit. They are all aluminum and represent the relationship between the main wing spar and the rear wing spar.  There is a short piece of wing spar that inserts into the spar center section, complete with the connecting bolt holes, and a short piece of the rear spar.  The jig sets the distance, front to back and the vertical and horizontal angles.  It is primarily used to accurately locate the rear spar attach plate, assist in cutting holes in the side skins and to assist with the flap actuator installation.  See photos. The last photo shows a mock-up of the flap attached to the rear spar of the jig.  Let me know if you have questions.

 

 Jay Bannister

 

   

 

   

 

 --

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z601a(at)anemicaardvark.c
Guest

Posted: Sun Aug 09, 2009 5:51 am Post subject: 601xl spar insert

On Sunday 09 August 2009 06:35, K Dilks wrote:

 	  Quote: 	
		   



 Hello,

 Its Sunday and I am stuck/ confused.

 I understand i need to make a wing jig from plywood , but can anyone

 explain about the part mentioned in the photo guide called the spar insert.

 Is this supposed to come from ZAC ready made or am i supposed to make it? I

 cant find the insert nor material to make it from!

  Building from a full kit.



 Thanks for any help, bit urgent as now my day has stopped!


	


I've had the same question. What I've learned so far is that it appears if one 

has a recent kit, with predrilled holes, the spar insert is not required. 



As I understand it, the spar insert allows one to align the correct location 

for the rear frame channel w.r.t. the spar and spar carry through. Dwg 6B13 

shows this.



My guess is, if you have a newer kit, you do not need these parts, and hence, 

they are not included.  I'm at roughly the same point in building, so if 

someone knows something contrary to this, please enlighten me and the others.

==============================================

   You can check on my aircraft construction     

progress at: http://www.mykitlog.com/santaigo

=================================================

               Jim B. Belcher

    BS, MS Physics, math, Computer Science

                  A&P/IA

           Instrument Rated Pilot

     General Radio Telephone Certificate

     Retired Aerospace Technical Manager

=================================================

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skyriderekm

Joined: 28 Feb 2009
Posts: 10

Posted: Sun Aug 09, 2009 2:08 pm Post subject: Re: 601xl spar insert

Dear Jim and all,



I picked up my 650 kit 2 weeks before Christmas last year.  I came to the exact same point as everyone else had and called Zenith.  Roger told me exactly what several was told, "the jig is NOT needed".  I too have the pre-punched skins.  It still to this day, sticks in my mind what if I'm off or I cut too much out of the skin, etc., etc.  The rear fuselage went well and the front pans was OK too.  The problem came when I tried lining up those pre-punched holes where the upright channels in front of and behind the landing gear channel is at.  The back of the seat uprights was off too.  I ended up having to drill another line of holes and fill their holes with blank rivets.  It looks OK but my EAA/DAR Tech Advisor looked at it and asked, "what are those extra holes for"??  He laughed when I explained it to him and said, "well only you, I and the factory knows".  You can bet I DID call and talk to the Factory.  They did offer a new set of skins without the pre-punched holes, but who would want to tear it all back apart and start again???  Certainly not me!! 



I hope all of this sheds some light for you.  If I had it to do again, I would try finding someone with a jig that way you will KNOW it is right.  Keep in mind that the 650 center main spar is only 7 degrees so if you do use someone else's 601 jig, that angle will be off those 2 degrees. 



Tailwinds Always,



Larry Hursh  

Edwardsburg, MI

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Davcoberly(at)wmconnect.c
Guest

Posted: Sun Aug 09, 2009 2:35 pm Post subject: 601xl spar insert

I too had the prepunched skins and the jigs were included and I still was a little wide between the spars and had to put shims between the rear spar and attach plates after I called and talked to Roger he said it would be OK. I also had a lot of trouble getting my side skin holes to match up with uprights and seat backs I had to make some wider angles and move stuff around to make it work after another call to Roger. It all looks good now being its flying   I think one would have less problems without the prepunched skins. David Coberly  [quote][b]

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chuck960

Joined: 11 Mar 2009
Posts: 44
Location: PA

Posted: Sun Aug 09, 2009 10:13 pm Post subject: Re: 601xl spar insert

I was wondering when this issue would come up. I hit this point in my 650 build a couple months ago. First of all I followed the plans and the drawing and made the cutout in the rear side skin to what would be the 601 design. So I have a gap in the side skin just behind the rear wing attachment. To make matters worse Zenith sent me the 601 side skins. So long story short they replaced the side skins and the top longerons. Check your seat parts and arm rest 6B18-1 aginst the drawing for dimensions. These were wrong also. The rear of the side skin should reflect the change in the wing angle. The best thing to do is borrow the wing jigs from one of out 601 brothers. I don't believe at this point that it is possible to get the rear wing attachment correct without the jigs. The picture is before I got the correct skins. Notice the gap behind the attachment point. 

Its late here so I have had to keep this short. If I confused everyone I'll try to clear it up later.

Chuck Dean

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