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wing flap predrilled hole rivet conflict

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z601(at)anemicaardvark.co
Guest

Posted: Sat Mar 07, 2009 3:40 pm Post subject: wing flap predrilled hole rivet conflict

I discovered a problem with the pre-drilled holes in part 6W1-2, which I 

suspect is common to all copies of this part. I sent the following message to 

Zenith today; when I get a response, I will post it:



"The predrilled holes in the flap skin, part 6W1-2, may have a conflict. The 

rearmost top and bottom holes in the skin are too close to each other to 

allow a rivet to be inserted from both sides. 



I discovered this when I had already riveted an A5 rivet in the top hole, and 

attempted to insert a rivet in the bottom hole opposite. 



Since the holes are already present, please advise on the recommended method 

of repair for the holes on the bottom skin, and your recommended work around 

when I assemble the next flap."



If you have predrilled flap skins, if you have not already seen this problem, 

I suspect you will.

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

                Jim B Belcher

    BS, MS Physics, Math, Computer Science

                  A&P/IA

     Retired aerospace technical manager

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

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scottbevier

Joined: 19 Jun 2007
Posts: 8

Posted: Sat Mar 07, 2009 7:54 pm Post subject: wing flap predrilled hole rivet conflict

Jim,



I experienced the same problem with the flap skins. Zenith said to elongate the bottom holes

with a file just enough to allow the bottom rivet to clear the one on top. That worked out ok for me.

Elongate the hole parallel to the rib.

You'll need to use a hand riveter. Insert the bottom rivet at an angle and slowly squeeze the riveter as you 

slowly bring the rivet head normal to the skin. As the rivet is pulled it starts to get shorter and should

clear the top rivet. The trick is to have the rivet head normal to the skin before the rivet expands to the hole diameter.

Go slow and be cautious.



Scott Bevier

601XL



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Afterfxllc(at)aol.com
Guest

Posted: Sat Mar 07, 2009 8:08 pm Post subject: wing flap predrilled hole rivet conflict

Jim

  

 Someone posted this same question a while back. The way I handled this was  to remove the stem from the rivet and then cut the rivet to make it shorter and  then re insert the stem and then it should clear. If you try and make it work  the way it is it usually looks like crap and then you will try and remove it to  try again and then it gets worse.

  

 Jeff

  	  Quote: 	
		  I    discovered a problem with the pre-drilled holes in part 6W1-2, which I    

suspect is common to all copies of this part. I sent the following message    to 

Zenith today; when I get a response, I will post it:



"The    predrilled holes in the flap skin, part 6W1-2, may have a conflict. The    

rearmost top and bottom holes in the skin are too close to each other to    

allow a rivet to be inserted from both sides. 



I discovered this    when I had already riveted an A5 rivet in the top hole, and 

attempted to    insert a rivet in the bottom hole opposite. 



Since the holes are    already present, please advise on the recommended method 

of repair for the    holes on the bottom skin, and your recommended work around 

when I assemble    the next flap."



If you have predrilled flap skins, if you have not    already seen this problem, 

I suspect you will.

	


 

  

 A Good Credit Score is 7001325337/aol?redir=http:%2F%2Fwww.freecreditreport.com%2Fpm%2Fdefault.aspx%3Fsc%3D668072%26hmpgID%3D62%26bcd%3DfebemailfooterNO62"> See yours in just 2 easy steps!

  [quote][b]

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z601(at)anemicaardvark.co
Guest

Posted: Sun Mar 08, 2009 8:46 am Post subject: wing flap predrilled hole rivet conflict

I appreciate all the responses I've received to this question. I will probably 

wait until I receive a formal response from Zenith before acting. If I 

haven't received a response in a reasonable length of time, I'll review the 

ideas you guys and gals provided, and use either the one I consider the best, 

or some mix thereof.



I believe Zenith needs to be reminded when problems like this exist, not once, 

but each time it happens. This problem has obviously been here for some time, 

but Zenith has neither corrected it, nor issued an errata advising of its 

existence and a workaround.



That's, in my view, possibly more a reflection of human nature, and the fact 

things get lost in the heap, than something negative about them. But if they 

aren't tapped on the shoulder each time it happens, it's easy to forget.



I would also like a formal response from them to file, so that, if the issue 

ever arises, I can point to the reason for my choice. Or, alternatively, say 

I requested guidance, but received none from the kit manufacturer.

-- 

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

                Do not archive.

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

                Jim B Belcher

    BS, MS Physics, Math, Computer Science

                  A&P/IA

     Retired aerospace technical manager

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

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jaybannist(at)cs.com
Guest

Posted: Sun Mar 08, 2009 9:14 am Post subject: wing flap predrilled hole rivet conflict

Jim,

 

 I think there is a bigger point here.  Sooner or later in your construction adventure, there are going to be many and varied issues that you will need to figure out how to do yourself. These are usually items that are not structural or airworthiness issues.   As you get further and further into your project, you are going to find that the specificity of Zenith's instructions begins to taper off.  By then, it is assumed that you have developed a habit of solving problems without a lot of hand-holding.  Once you get the kit completely assembled, then you are on your own BIG TIME !  I probably spent as much time on the electrical system, panel and FWF as I did on the airframe.  And of that time, probably 80% was spent designing or problem solving.   

 

 Remember, a big part of "experimental" is the education part.  So go get "smart" and HAVE FUN !!

 

 Jay Bannister

 

   

 

   

 

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z601(at)anemicaardvark.co
Guest

Posted: Sun Mar 08, 2009 9:27 am Post subject: wing flap predrilled hole rivet conflict

Jay, as an A&P/IA, and when working as an engineer, I've had to solve my share 

of problems without much guidance. That may turn out to be the case with 

Zenith, and I'd like to think I'm up to the task. I expect to learn, most 

likely some things I didn't expect to learn.



 It may well be that the scope and number of problems with the Zenith design 

will grow. I'll take your word for that, as you're much further along the 

building process than I.



However, I paid Zenith for a kit with plans, with the expectation that things 

would either be correct, or they would be corrected. I don't believe that's 

an unreasonable expectation. Whether it's realistic or not is another 

question.



Meanwhile, I appreciate the ideas I get from this forum. Lacking information 

from Zenith, I like to see if someone else has had the same problem first, 

and how they solved it. Heck, I'm not proud: I'll borrow ideas from 

anyone. 



On Sunday 08 March 2009 12:13, jaybannist(at)cs.com wrote:



 	  Quote: 	
		   I think there is a bigger point here.? Sooner or later in your construction

 adventure, there are going to be many and varied issues that you will need

 to figure out how to do yourself. These are usually items that are not

 structural or airworthiness issues. ? As you get further and further into

 your project, you are going to find that the specificity of Zenith's

 instructions begins to taper off.? By then, it is assumed that you have

 developed a habit of solving problems without a lot of hand-holding.? Once

 you get the kit completely assembled, then you are on your own BIG TIME !?

 I probably spent as much time on the electrical system, panel and FWF as I

 did on the airframe.? And of that time, probably 80% was spent designing or

 problem solving. ?



 Remember, a big part of "experimental" is the education part.? So go get

 "smart" and HAVE FUN !!




	




-- 

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

                Do not archive.

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

                Jim B Belcher

    BS, MS Physics, Math, Computer Science

                  A&P/IA

     Retired aerospace technical manager

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

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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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