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Upgrade Question - Main Spar Carry Through

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Scotsman

Joined: 27 Aug 2007
Posts: 89
Location: Johannesburg, South Africa

Posted: Tue Jun 01, 2010 9:40 am Post subject: Upgrade Question - Main Spar Carry Through

Evening List,  a quick couple of questions regarding the main spar carry through piece:



Firstly, after having installed all the various new pieces on the spar carry through I was trial fitting it onto the cabin floor.  Obviously the assembly is a bit wider than before to accommodate the thicker spar root.  Ultimately when I cleco in the aft set of holes to the cabin floor I had a quick look at the forward set to see where they fall in relation to the holes forward holes.  Basically the new forward holes will "clip" the old forward holes.  Is this correct as it seems messy and makes me question a) whether I am doing it correctly and b) whether this is structurally ok?



Secondly, after having trial fitted the spar carry through together I tried to push my centre punch through a couple of the holes to test alignment (with the holes on the other web).  The two set of holes do not seem perfectly aligned.  Did anyone else encounter this and if so what was the solution?  FYI the holes on each web are very tight as I was concerned about the comments on the list about loose fittings etc.  Should the spar holes accept the bolt dropping in or should it be tapped in with a rubber mallet or the like.



Any advice in regards to either question would be much appreciated and apologies if anyone has already raised and answered the above questions.



James

_________________
Cell +27 83 675 0815

psm(at)att.net
Guest

Posted: Tue Jun 01, 2010 2:02 pm Post subject: Upgrade Question - Main Spar Carry Through

Hi James,



I haven't made it that far yet, but I have started thinking about it a

little.  The side skin will be a problem unless we do something to replace

the skin around the carry-through.  This is not as bad as it sounds since

the new uprights are attached to both longerons instead of just the bottom

one as in the original design.  That makes the skin question a little bit

less important.  Perhaps some sort of patch over the old holes would solve

that problem - either with or without removing the old skin around this

area.



I don't have any ideas about the alignment question.  Part of this problem

is the fact the front part of the fuselage "Floats" compared to the rear

part until the carry-through is fastened in place.



Good luck,



Paul

XL installing upgrade (slowly)

--

wa7dvd

Joined: 27 Oct 2006
Posts: 11
Location: Salt Lake City, Ut

Posted: Tue Jun 01, 2010 8:11 pm Post subject: Re: Upgrade Question - Main Spar Carry Through

I was working on the same thing today.  I talked to Roger (ZAC) this morning about the same thing.  Since I had not drilled the front flange yet I laid out a complete to line of holes half way between to old holes.  Roger said just leave the old holes empty.  With the spar out, we measured and pilot drilled the new line through the floor.  Then with the spar in place we back drilled up through the floor and spar.  It lined up well.  So far as holes in the side skins, the "T" stiffener will cover all visible holes along the uprights.

_________________
BK Johnson
Zodiac 601XLb
Jabiru 3300a
N601BK

Scotsman

Joined: 27 Aug 2007
Posts: 89
Location: Johannesburg, South Africa

Posted: Tue Jun 01, 2010 8:47 pm Post subject: Re: Upgrade Question - Main Spar Carry Through

Thanks wa7dvd.  That seems to be a solution as I think that the upgrade manual suggests drilling through the existing holes in the forward flange of the spar which will clip the old cabin floor holes.  I note that in one of the upgrade videos you can see that their clecos are squint because of this.  Is there sufficient edge distance between the old and new holes in your method?



Anyone else got a solution for the bolt hole alignment on the upgraded spar?



James

_________________
Cell +27 83 675 0815

Scotsman

Joined: 27 Aug 2007
Posts: 89
Location: Johannesburg, South Africa

Posted: Tue Jun 01, 2010 8:53 pm Post subject: Re: Upgrade Question - Main Spar Carry Through

Hi Paul,  I was considering "extending" the T section on the side of the fuselage downwards purely for aesthetic reasons.  This would allow both covering all of the old forward upright holes and allowing you to cleanly recut the hole for the spar carry through to match the new upgraded dimensions.



Probably lots of work to get a nice fit though. 



j

_________________
Cell +27 83 675 0815

wa7dvd

Joined: 27 Oct 2006
Posts: 11
Location: Salt Lake City, Ut

Posted: Tue Jun 01, 2010 9:04 pm Post subject: Re: Upgrade Question - Main Spar Carry Through

Hi James,



The old rivet line is pitch 30 so going between still leaves 15mm.  Roger told me that would be just fine.  Sorry for not signing my last note.



-Bruce-

_________________
BK Johnson
Zodiac 601XLb
Jabiru 3300a
N601BK

Scotsman

Joined: 27 Aug 2007
Posts: 89
Location: Johannesburg, South Africa

Posted: Tue Jun 01, 2010 9:51 pm Post subject: Re: Upgrade Question - Main Spar Carry Through

Thanks Bruce. I was being lazy and not walking downstairs to have a look. 15 mm is definitely sufficient. James

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Cell +27 83 675 0815

dgardea(at)gmail.com

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

Posted: Wed Jun 02, 2010 9:50 am Post subject: Re: Upgrade Question - Main Spar Carry Through

Bruce - thanks for making the call to ZAC in the rivet holes thru that forward bottom doubler on the center spar. I unfortunately already backdrilled these so will need to add additional rivet holes to miss the holes in the fuse floor. On a related topic .. did anyone notice that the center spar doublers were shipped at length 945 when the ZAC upgrade plans call for a length of 940 on all the doublers. I just finished drilling and deburring all the doublers and wondering if I will need to trim these to avoid interference with the front and aft uprights? Someone who has already clecoed their center spar parts together and tested for clearance may already know the answer. Thanks!



Dave Gardea

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

DaveG601XL

Joined: 27 Oct 2006
Posts: 351
Location: Cincinnati, Oh

Posted: Wed Jun 02, 2010 11:16 am Post subject: Re: Upgrade Question - Main Spar Carry Through

Dave,



There will be trimming required of the doublers to provide clearance to the wing uprights 6ZU2-6.



Good luck,

_________________
David Gallagher
Cincinnati, OH area

dgardea(at)gmail.com

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

Posted: Wed Jun 02, 2010 12:00 pm Post subject: Re: Upgrade Question - Main Spar Carry Through

Dave,



Thanks for the heads up on this. Like James, I will be trial fitting the center spar in the fuse and checking the fit before any riveting. 



Thanks,



Dave Gardea

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

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