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naumuk(at)alltel.net
Guest

Posted: Sat Dec 23, 2006 7:21 am Post subject: Tips

Mike-

     I agree with you, but given the  variation inherent with each project, the only solution I can come up  with is a factory template that would go OVER the top skins and locate off  the inboard end of the spar. Once the template is located, trace  around the template edges, then cut the tip skins.

     Then, have fiberglass tips that  have extra long flanges and a molded in reference line. Locate the tip to the  inboard end of the spar using the reference lines and drill your rivet holes.  Then, trim the excess flange.

     Anyone have a better idea? Let's  face it, this is a major PIA that has never been satisfactorily  addressed.

 Bill Naumuk

HDS Fuselage

Townville, Pa

  	  Quote: 	
		  

If anyone wants to suggest that that a CH design cannot be    improved (vgs anyone?), you have obviously either not done, or you have    forgotten, the half-assed wingtip design. 



Michael in NH

Guess what    I part I'm working on!



    

	
    [quote][b]

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pmaxpmax(at)HOTMAIL.COM
Guest

Posted: Sat Dec 23, 2006 1:38 pm Post subject: Tips

I made a template out of Christmas wrapping paper, based on the factory dimensions.  I then laid it out on the top of the wing (and bottom) and cut it about 20 mm too long, and tested the fit of the leading edge fiberglass piece.  It needed a little help, so I hit it with a heat gun for a while and reformed it slightly.  Once I was OK with it, I made the final cut.  the aluminum piece at back is nothing difficult.

 

I know this seems like a pain, and it did to me too when I was doing it.  However, when it's behind you, it's not as bad as it seems at the time.

  

 All this is based on the XL, assuming the HDS is a similar design.  If it is not, please delete now.

Phil Maxson

601XL/Corvair

Northwest New Jersey

  	  Quote: 	
		    From: naumuk(at)alltel.net

To: zenith-list(at)matronics.com

Subject: Zenith-List: Tips

Date: Sat, 23 Dec 2006 10:21:25 -0500



     Mike-

     I agree with you, but given the variation inherent with each project, the only solution I can come up with is a factory template that would go OVER the top skins and locate off the inboard end of the spar. Once the template is located, trace around the template edges, then cut the tip skins.

     Then, have fiberglass tips that have extra long flanges and a molded in reference line. Locate the tip to the inboard end of the spar using the reference lines and drill your rivet holes. Then, trim the excess flange.

     Anyone have a better idea? Let's face it, this is a major PIA that has never been satisfactorily addressed.

 Bill Naumuk

HDS Fuselage

Townville, Pa

  	  Quote: 	
		  

If anyone wants to suggest that that a CH design cannot be improved (vgs anyone?), you have obviously either not done, or you have forgotten, the half-assed wingtip design. 



Michael in NH

Guess what I part I'm working on!



  

	
 	  Quote: 	
		  



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arget=_blank>http://www.matronics.com/Navigator?Zenith-List



	
	
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agustafson(at)chartermi.n
Guest

Posted: Sat Dec 23, 2006 2:37 pm Post subject: Tips

Just chiming in here for what it's worth (not much). Being  a plans builder and having purchased nothing from Zenith since the plans, I  decided that it was easier to build metal forward tip skins rather than lay up  fiberglass, mold etc. They came out great and weren't that hard to do. I think  the second one was about 4 hours from start to riveting. Made the Whelan light  mount separate out of pine with 2 coats of epoxy and paint.

  

 Aaron Gustafson   do not  archive

   [quote][b]

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naumuk(at)alltel.net
Guest

Posted: Sun Dec 24, 2006 7:24 am Post subject: Tips

Phil-

     The HDS plans don't give you  coordinates for laying out the tip cuts- you're supposed to install the metal  portion of the tip, then use a marker taped to a stick to trace the cut  line. This difference doesn't warrant deleting your post.

     My problem is, even though the job is  behind me and turned out better than reported by some listers, I'm suffering  from "It could be better still" remorse. 

     I decided to polish the majority of my  project and trim paint only the leading edges and wing tips. I don't see any way  out of using a couple of ounces of FiberFil to make things right in those areas.  On the other hand, I've seen Jeff Small's plane and he swears he used no filler  at all. I believe it all comes down to the quality of the individual  fiberglass tip. (That and not running the leading edge of your right outboard  into a doorknob!)

     Aaron Gustafson custom made his tip to  fit his project, as did Larry Mac, and both are happy with the results. It would  seem to me that redesigning the fiberglass tip to be more forgiving during  installation would be the solution.  

 Bill Naumuk

HDS Fuselage

Townville, Pa

 [quote]



I know this seems like a pain, and it did to me too    when I was doing it.  However, when it's behind you, it's not as bad as    it seems at the time.

 

All this is based on the XL, assuming the    HDS is a similar design.  If it is not, please delete now.

 	  Quote: 	
		  

	
[b]

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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:

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pmaxpmax(at)HOTMAIL.COM
Guest

Posted: Sun Dec 24, 2006 2:51 pm Post subject: Tips

I also bought some filler products, thinking I would use them and paint.  I also thought I couldn't polish my plane, since it had some dents and "smiles" in the leading edges due to my poor handling of the leading edge skins.  Guess what.   I didn't use any of the filler, and I polished it anyway.  Bill Clapp, KR2 and Corvair builder, started working on my smiles and dents with a suction cup tool and worked out all the problems.  When you polish it up, you'd be surprised at how much people are overwhelmed with the shine, and tend to ignore the little blemishes.

  

 Don't get discouraged.  It will all work out in the end and unless you really butchered the tips, I bet you will be pleased with the polishing job.  You won't be too happy will all the work it takes to get it polished though!



Phil Maxson

601XL/Corvair

Northwest New Jersey

  	  Quote: 	
		     .ExternalClass P {padding-right:0px;padding-left:0px;padding-bottom:0px;padding-top:0px;} .ExternalClass {font-size:10pt;font-family:Tahoma;}   Phil-

     The HDS plans don't give you coordinates for laying out the tip cuts- you're supposed to install the metal portion of the tip, then use a marker taped to a stick to trace the cut line. This difference doesn't warrant deleting your post.

     My problem is, even though the job is behind me and turned out better than reported by some listers, I'm suffering from "It could be better still" remorse. 

     I decided to polish the majority of my project and trim paint only the leading edges and wing tips. 

 <<SNIP>>

	
Get into the holiday spirit, chat with Santa on Messenger.px?locale=en-us' target='_new'>Ho-Ho-Ho!  [quote][b]

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naumuk(at)alltel.net
Guest

Posted: Mon Dec 25, 2006 5:24 am Post subject: Tips

Phil-

     I've come to the conclusion that  polishing isn't for the impatient! Merry Christmas!

                                   do not archive

 Bill Naumuk

HDS Fuselage

Townville, Pa

 [quote]   ---

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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:

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