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lwhitlow
Joined: 15 Jan 2006
Posts: 76
Location: Valparaiso Indiana
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 Posted: Sat Jun 05, 2010 10:15 am Post subject: Center Spar Upgrade Question |
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Hi all
I'm working on the center spar upgrade section and I seem to be having a brain cramp
I've drilled and fitted all the doublers and I'm at the point in the photo guide where you put the two haves back together and bolt so you and drill out the 1/4 holes for the outboard spacers (page 16,17,18 of the upgrade photo assembly guide)
Now that its .125 wider the top flange doesn't want to fit under the top cap/ Seat support of the other half of the spar. The flange is pushed out by the larger spacers and I can't get it to go up tight.
OK what's the trick?? Do I trim the flange a bit (edge distance no issue my spars holes are very close to the bend). or to I put a slight bend in the spar web to push the flange back to create more room
I admit I'm a bit baffled as to how Zenith expected to widen the Center spar gap by .125 and still have the holes on top line up. What am I missing??
Larry Whitlow
N69102 (reserved) 601XLB (B in progress)
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dgardea(at)gmail.com
Joined: 26 Mar 2007
Posts: 50
Location: Indianapolis, IN
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| Posted: Mon Jun 07, 2010 6:37 am Post subject: Re: Center Spar Upgrade Question |
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Larry,
Struggled this past weekend with the exact same interference from the angle on the existing rear center spar web. I was just on the phone with Caleb at Zenith and after describing the problem he claims I should not have any problem with the fit and that I must be putting parts in out of order. My initial question was whether the pitch 20 on the solid rivets was correct as it will likely hit existing holes on the top flange of this rear center spar web. He said not a problem if it did since there's a double on both sides sandwiching that part. In fact, he said you could even cut that flange off but it would of course screw up the spar angle.
I intend to take my vixen file and remove what little is necessary from the existing rear center spar web angle to eliminate the interference with the top spar cap and allow me to get to bolts, spacers and washers in easily.
Dave
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Dave Gardea
CH650 - Corvair - flying!
http://n631dg.t15.org/home.html |
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Afterfxllc(at)aol.com
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| Posted: Mon Jun 07, 2010 9:25 am Post subject: Center Spar Upgrade Question |
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Dave
You have to tape the bolts so they are just outside the washers and then place the center section upside down on the bench and clamp the top to the bench and with a little force push the other half down until the bolts line up and then tap the heads of the bolts with a hammer to get them started and then it will align.
I have done 7 of them and no trimming was required.
If anyone has any questions they can call me 502-644-8123.
Jeff
In a message dated 6/7/2010 10:38:44 A.M. Eastern Daylight Time, dgardea(at)gmail.com writes:
| Quote: | --> Zenith-List message posted by: "dgardea(at)gmail.com" <dgardea(at)gmail.com>
Larry,
Struggled this past weekend with the exact same interference from the angle on the existing rear center spar web. I was just on the phone with Caleb at Zenith and after describing the problem he claims I should not have any problem with the fit and that I must be putting parts in out of order. My initial question was whether to pitch 20 on the solid rivets was correct as it will likely hit existing holes on the top flange of this rear center spar web. He said not a problem if it did since there's a double on both sides sandwiching that part.
I intend to take my vixen file remove what's necessary from the rear center spar web angle to eliminate the interference and allow me to get to bolts, spacers and washers in easily.
Dave
--------
Dave Gardea
601XL - Corvair
working on wiring panel and upgrade kit
http://home.comcast.net/~davegardea/
Read this topic online here:
http://forums.matronics.com/viewtopic.php?p=300335#300335===============================================
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dgardea(at)gmail.com
Joined: 26 Mar 2007
Posts: 50
Location: Indianapolis, IN
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| Posted: Mon Jun 07, 2010 9:33 am Post subject: Re: Center Spar Upgrade Question |
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Jeff,
Thanks for the tip! I will try your approach.
Dave
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Dave Gardea
CH650 - Corvair - flying!
http://n631dg.t15.org/home.html |
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leinad
Joined: 19 Sep 2006
Posts: 283
Location: Central Virginia
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| Posted: Mon Jun 07, 2010 5:23 pm Post subject: Re: Center Spar Upgrade Question |
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I rolled the edge of the rear half slightly and it made a nice fit without loosing any more edge distance.
http://daniel.dempseyfamily.us/zodiac/upgrade/benddrill.jpg
Dan
| lwhitlow wrote: | Hi all
I'm working on the center spar upgrade section and I seem to be having a brain cramp
I've drilled and fitted all the doublers and I'm at the point in the photo guide where you put the two haves back together and bolt so you and drill out the 1/4 holes for the outboard spacers (page 16,17,18 of the upgrade photo assembly guide)
Now that its .125 wider the top flange doesn't want to fit under the top cap/ Seat support of the other half of the spar. The flange is pushed out by the larger spacers and I can't get it to go up tight.
OK what's the trick?? Do I trim the flange a bit (edge distance no issue my spars holes are very close to the bend). or to I put a slight bend in the spar web to push the flange back to create more room
I admit I'm a bit baffled as to how Zenith expected to widen the Center spar gap by .125 and still have the holes on top line up. What am I missing??
Larry Whitlow
N69102 (reserved) 601XLB (B in progress) |
| | - The Matronics Zenith-List Email Forum - | | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
http://www.matronics.com/Navigator?Zenith-List |
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Scratch building XL with Corvair Engine |
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lwhitlow
Joined: 15 Jan 2006
Posts: 76
Location: Valparaiso Indiana
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| Posted: Mon Jun 07, 2010 8:48 pm Post subject: Re: Center Spar Upgrade Question |
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| dgardea(at)gmail.com wrote: | Larry,
Struggled this past weekend with the exact same interference from the angle on the existing rear center spar web. I was just on the phone with Caleb at Zenith and after describing the problem he claims I should not have any problem with the fit and that I must be putting parts in out of order. My initial question was whether the pitch 20 on the solid rivets was correct as it will likely hit existing holes on the top flange of this rear center spar web. He said not a problem if it did since there's a double on both sides sandwiching that part. In fact, he said you could even cut that flange off but it would of course screw up the spar angle.
I intend to take my vixen file and remove what little is necessary from the existing rear center spar web angle to eliminate the interference with the top spar cap and allow me to get to bolts, spacers and washers in easily.
Dave |
Well, I did some light tapping with a dead blow mallet and it popped into place. So I think thats OK
But I may have created a new issue. I saw on the prints that the new rivet line on the top of the center spar is Pitch 20. Are we not using the previous rivet holes on the top of the spar ?? Or is the a new line and the old holes are covered by the doubler? If we aren't using the old holes on the top flange then I'm gonna have to get a new doubler cause I backdrilled the thing from the old holes in the top of the spar
Let me know If I need to call Roger and order a part
Larry
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dgardea(at)gmail.com
Joined: 26 Mar 2007
Posts: 50
Location: Indianapolis, IN
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| Posted: Tue Jun 08, 2010 5:02 am Post subject: Re: Center Spar Upgrade Question |
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Larry,
I did the same exact thing .. I had backdrilled the top doubler following the directions from Zenith. I ordered three new parts yesterday: both top doublers and the forward bottom doubler. All will cost you about $50.
Dave
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Dave Gardea
CH650 - Corvair - flying!
http://n631dg.t15.org/home.html |
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