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Terrences Web Site

Builder:
Terrence Phillips
Location:
Corvallis, MT - USA
Aircraft:
Zenith Aircraft Co. - CH601XL
Manufacturer:   
http://www.zenithair.com/
Engine:
Jabiru - 3300
Prop:
Sensenich - 2A0J5R64Z-N Carbon Fiber Ground Adjustable - Constant Pitch

Welcome to my airplane builder’s-log website. I am building a Zenith 601XL from a complete kit delivered in February, 2007. I originally wanted to build a Cozy. But I decided I’d rather spend my retirement flying than building, so I set my sights on the RV-9A. Then I decided that light sport was the way to go. In the Fall 2006 time-frame the Zenair 601XL looked to me to offer the best combination of performance, building ease, proven design, and value. I visited the factory in Mexico, MO for a demo flight and committed to the 601XL. I believe that Zenith Aircraft offer the best combination of performance and value in the homebuilt light sport market.

A glance at my builder's log reveals that precious little has been done since April 6, 2008. There is a reason for that. On April 7, 2008, a 601XL lost a wing and crashed near Polk City, FL. That was the 4th 601XL wing loss accident since February 2006. I decided that I could not continue building until the cause for these accidents was determined, and something was developed to eliminate the problem.

Since then, I devoted more than two and a half years of building time to facilitating an independent engineering analysis of the 601XL through the auspices of the Zenith Builders Analysis Group (ZBAG). Twenty-nine other builders joined me to make ZBAG happen. Immediately following the Agnos, AR accident on November 6, 2009 the FAA issued a Special Airworthiness Bulletin, CE-10-08, recommending that all owners of 601XL's and 650's ground their airplanes until they comply with a forthcoming Safety Directive / Safety Alert from Zenair. Subsequently, on Nov. 12, the FAA issued a directive to, "suspend the issuance of new airworthiness certificates to any and all variants of Zodiac CH601XL and CH650 airplanes," until, "such time that the applicant submits adequate evidence that the applicant's aircraft has been modified in a manner consistent with," "AMD Safety Directive/Alert ... issued on November 7,2009."

In December 2009, Zenair finalized plans for upgrading 601XL/650 aircraft to address the concerns raised by the FAA and others. I believe that the upgrade will eliminate the possibility of flutter and that the other mods will increase the safety margins in the structure which will produce a 601XL aircraft that is just as safe as other LSA kit aircraft. I commend Zenair addressing the problems with the aircraft. I ordered the upgrade kit immediately upon Zenair’s announcement of availability, and I received my kit on January 11. I am proceeding slowly with my build. I hope that my build rate will increase as I get back into the rhythm. I look forward to completing and flying my 601XL. (Rev. 5/27/10)


Recent Activity
First Photo
Date

Work Log Summary

Spar cap after initial blending
02-24-2012
Blend out damage to L-bottom spar cap
L Aileron top view
05-29-2011
Reassemble left aileron w/ balance & hinge
Aileron w/ piano hinge
05-28-2011
Continued.: balance arm & piano hinge
Piano hinge clecoed in place
05-26-2011
Install balance arm & piano hinge on right aileron
Notch in reinforcing angle to clear cable
02-17-2011
Reinstall aileron trim servo
Chips glued into primer
02-11-2011
Deburr, scour, clean, and prime new aileron joints
R Aileron counter-balance arm & ribs
01-26-2011
Install R aileron counter-balance arm & ribs
Right aileron pilot pilot drilled for piano hinge
01-22-2011
R aileron piano hinge conversion
01-16-2011
Revised mod process for right aileron
L Aileron with piano hinge
01-15-2011
Drill piano hinge attach holes to #30
Rib alignment as done
01-14-2011
Drill inboard rib for left aileron counterbalance
Ribs aligned per photoguide instructions
01-05-2011
Drill inboard rib for left aileron counterbalance
11-13-2010
Drill out gussets for L-aileron
L-angle pilot drilled to aileron front
11-10-2010
Pilot drill L-aileron to hinge
L Aileron flange ready to drill
11-07-2010
Prepare & pilot drill L Aileron for piano hinge
Aileron horn doubler
11-04-2010
Add L-angle back doubler behind aileron horn
Cutout for balance arm
11-03-2010
Mod left aileron to accept counter balance
Drilling off the A4 rivet heads
10-25-2010
Disassemble left aileron to install balance, Hinge
Reaming the 5/16
10-21-2010
Drill & ream holes for left spar root doubler plat
Front side of spar
08-13-2010
Remove web doubler from right spar
08-07-2010
Left spar cap rivet removal: bottom root
Extruded angle riveted to L spar
08-06-2010
Rivet the left top spar cap back together
Bend in bottom spar cap at doubler
08-06-2010
Confer with Zenair Re bend in R Spar at doubler

08-02-2010
Drill extra hole for AN3 bolt in extrusion & prime
07-29-2010
Back drill rivet holes through the spar cap extrus











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