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Zenith wing skins

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dgardea(at)gmail.com

Joined: 26 Mar 2007
Posts: 50
Location: Indianapolis, IN

Posted: Sun Jun 03, 2007 6:47 pm Post subject: Zenith wing skins

Hello 601XL kit builders .. anyone receive bottom wing skins with the tiedown slot precut to the outboard side (flange side) of rear rib #9? Of course the plans have you mounting the tiedown on the inboard side of rr #9 which makes sense. I am now faced with developing some way of mounting the tiedown by bringing it out even with the flange to match the very generous precut slot in the skin. Anyone run into this and develop a solution? Also a little odd that Zenith has chosen to predrill the spar edge of the top and bottom skins since the nose skin overlaps those skins thus rendering the pre-drilled holes kinda useless. I suppose I will try to tuck the nose skin under the top and bottom skins to try to transfer those predrilled holes to the nose skin before drilling and then move back on top to cleco. Your experience with this and solutions are appreciated.



Thanks,



Dave Gardea

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Dave Gardea
CH650 - Corvair - flying!
http://n631dg.t15.org/home.html

rsteele(at)rjsit.com
Guest

Posted: Sun Jun 03, 2007 7:24 pm Post subject: Zenith wing skins

Can't speak to the tiedown, but with regards to the skins, this is  

exactly the way the current rudder kit works.  Slip the nose skin  

under the tail skin, drill, remove and then cleco the nose skin over  

the tail skin.



Ron

On Jun 3, 2007, at 10:47 PM, dgardea(at)gmail.com wrote:



 	  Quote: 	
		   

 <dgardea(at)gmail.com>



 Hello 601XL kit builders .. anyone receive bottom wing skins with  

 the tiedown slot precut to the outboard side (flange side) of rear  

 rib #9? Of course the plans have you mounting the tiedown on the  

 inboard side of rr #9 which makes sense. I am now faced with  

 developing some way of mounting the tiedown by bringing it out even  

 with the flange to match the very generous precut slot in the skin.  

 Anyone run into this and develop a solution? Also a little odd that  

 Zenith has chosen to predrill the spar edge of the top and bottom  

 skins since the nose skin overlaps those skins thus rendering the  

 pre-drilled holes kinda useless. I suppose I will try to tuck the  

 nose skin under the top and bottom skins to try to transfer those  

 predrilled holes to the nose skin before drilling and then move  

 back on top to cleco. Your experience with this and solutions are  

 appreciated.



 Thanks,



 Dave Gardea



 --------

 Dave Gardea

 601XL - Corvair

 working on wings

 http://home.comcast.net/~davegardea/





 Read this topic online here:



 http://forums.matronics.com/viewtopic.php?p=116275#116275

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p.mulwitz(at)worldnet.att
Guest

Posted: Sun Jun 03, 2007 8:44 pm Post subject: Zenith wing skins

Hi Dave,



I had to scrap my first wing because I followed the directions with 

perhaps less than perfect skill.  I damaged the spar cap angles by 

drilling the holes in the wrong places.  The original directions I 

had called for magically drilling the nose skin, rear skin, and spar 

cap angle all at once after building most of the wing.  I solved this 

problem in the next two wings by drilling the holes in the spar cap 

angles first -  long before installing the nose skin.



If you mark the center line of the spar cap angles and drill the rear 

skin to the spar before doing anything else (except perhaps aligning 

the skin with the rear ribs) then you will be sure of making these 

critical holes in the right places.  You can then drill the nose skin 

as mentioned by inserting it between the rear skin (once it is 

completely drilled and clecoed in place) and the spar.  You can press 

the nose skin into place using the web clamps as shown for the 

elevator.  When it comes time to rivet the three parts together just 

position the nose skin on top of the rear skin.



Paul

XL fuselage

At 07:47 PM 6/3/2007, you wrote:

 	  Quote: 	
		  



Hello 601XL kit builders .. anyone receive bottom wing skins with 

the tiedown slot precut to the outboard side (flange side) of rear 

rib #9? Of course the plans have you mounting the tiedown on the 

inboard side of rr #9 which makes sense. I am now faced with 

developing some way of mounting the tiedown by bringing it out even 

with the flange to match the very generous precut slot in the skin. 

Anyone run into this and develop a solution? Also a little odd that 

Zenith has chosen to predrill the spar edge of the top and bottom 

skins since the nose skin overlaps those skins thus rendering the 

pre-drilled holes kinda useless. I suppose I will try to tuck the 

nose skin under the top and bottom skins to try to transfer those 

predrilled holes to the nose skin before drilling and then move back 

on top to cleco. Your experience with this and solutions are appreciated.



Thanks,



Dave Gardea

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ashleyw(at)gvtc.com
Guest

Posted: Mon Jun 04, 2007 2:54 am Post subject: Zenith wing skins

Had the same problem with my skins.



I called Zenith and they approved the swapping of the ribs #9 from the right 

and left wings.  The tie down fits correctly if the rib flanges are inboard 

instead of outboard as shown on the drawings.



Floyd Wilkes

---

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dgardea(at)gmail.com

Joined: 26 Mar 2007
Posts: 50
Location: Indianapolis, IN

Posted: Mon Jun 04, 2007 3:32 am Post subject: Re: Zenith wing skins

Thanks to everyone for their quick and helpful replies!



Best regards,



Dave Gardea



do not archive

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_________________
Dave Gardea
CH650 - Corvair - flying!
http://n631dg.t15.org/home.html

dredmoody(at)cox.net
Guest

Posted: Mon Jun 04, 2007 5:58 am Post subject: Zenith wing skins

I'd convert the precut slot into an access hatch and make a new slot where it is supposed to go. First, however, make sure that you are lining the skin up properly and that the rib in question is located at the correct location. If all of that checks out, call the factory before proceeding. They may be able to spot the problem and suggest a better solution.



Dred

Do Not Archive



---- "dgardea(at)gmail.com" <dgardea(at)gmail.com> wrote: 

 	  Quote: 	
		   

 

 Hello 601XL kit builders .. anyone receive bottom wing skins with the tiedown slot precut to the outboard side (flange side) of rear rib #9? Of course the plans have you mounting the tiedown on the inboard side of rr #9 which makes sense. I am now faced with developing some way of mounting the tiedown by bringing it out even with the flange to match the very generous precut slot in the skin. Anyone run into this and develop a solution? Also a little odd that Zenith has chosen to predrill the spar edge of the top and bottom skins since the nose skin overlaps those skins thus rendering the pre-drilled holes kinda useless. I suppose I will try to tuck the nose skin under the top and bottom skins to try to transfer those predrilled holes to the nose skin before drilling and then move back on top to cleco. Your experience with this and solutions are appreciated.

 

 Thanks,

 

 Dave Gardea

 

 --------

 Dave Gardea

 601XL - Corvair

 working on wings

 http://home.comcast.net/~davegardea/

 

 

 

 

 Read this topic online here:

 

 http://forums.matronics.com/viewtopic.php?p=116275#116275

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Tim Juhl

Joined: 21 Mar 2006
Posts: 488
Location: "Thumb" of Michigan

Posted: Mon Jun 04, 2007 7:45 am Post subject: Re: Zenith wing skins

My skins (received the kit a year ago) did not have the holes predrilled for the LE flange nor did they have the slot for the tiedown ring cut.  They were, however, 18 mm short of what was called for in the drawings which resulted in having to recalculate the "Y" distances slightly when it came to trimming the wing tips (top skins).  It also had a few holes located at positions other than those called for in the plans.  There was nothing I couldn't deal with but it did result in a little head scratching before I felt confident to proceed.



I give ZAC credit for trying to make the process easier for us but I think sometimes they err themselves.  It is important to point these problems out to them so that if need be they can make adjustments to their CNC machine.  A gross error on their part would be justification to ask for a replacement.



For your problem, swapping ribs sounds like a simple solution.



Tim

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dgardea(at)gmail.com

Joined: 26 Mar 2007
Posts: 50
Location: Indianapolis, IN

Posted: Mon Jun 04, 2007 9:43 am Post subject: Re: Zenith wing skins

Hi Tim,



Thanks for the note. I should definitely call ZAC to let them know about the tiedown mis-cut on the bottom skin as you suggest. I plan to swap the #9 ribs as you guys recommended. Floyd, glad you had called ZAC and confirmed OK to do this. Paul, thanks for the advice on the spar cap angles .. I will likely take your approach with the next wing to be sure I have adequate web clearance. What a great forum and resource! .. I posted a note late last night and had three helpful replies already by the time I left for work today!



Dave

do not archive

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Dave Gardea
CH650 - Corvair - flying!
http://n631dg.t15.org/home.html

macstar(at)raider.co.nz
Guest

Posted: Mon Jun 04, 2007 11:45 am Post subject: Zenith wing skins

I drilled the holes in the spar caps first to ensure correct spacing and

edge distance. I then used the back drill method to first pick up the rear

skin and the nose skin. The back drill method uses a tool similar to the

flange finder tool shown on www.601ch.org/tools

Just remove the flange and put a solid csk 1/8 rivet in one of the pilot

holes. This rivet is placed in the spar cap hole and you drill using the

other pilot hole as a guide hole.  



Ian McClelland

601XL scratch builder

Flight controls finished. Wings 70% complete

New Zealand

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