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Date:  4-3-2008
Number of Hours:  1.00
Manual Reference:  6W8B 1-3
Brief Description:  Positioned nose skin--problems with prepunched hol

1. When positioning the nose skin, there were several problems:

- The nose skin is punched for a 30-gal gas tank, not the 24-gal tanks that I have. I.e., the rivet line for NR#4 is about 200-mm too far outboard.
- The prepunched holes do not line up well with the prepositioned rib locations. If I set NR#1 right on, then 2 & 3 are off a bit, but within edge specs. NR#6 is worse, but just does meet the spec. NR#7 is about 16-mm off. The prepunched holes do not even fall onto rib #7. See Figs. 1, 2, & 3.

2. While responding to a post on the Zenith-List regarding wing twist, realized that I had never actually measured the bottom skin that appeared to be too wide--so I measured it. The inboard end of the skin measures 917-mm vs. 910-mm on 6-W-8 and the outboard end measures 720-mm vs. 705-mm on the dwg. Duh. I can't believe that I didn't measure them when the problem 1st surfaced. So, the good news is that my right wing skeleton is (probably) just fine dimensionally, but the skin is just too wide.

3. Talked 2 or 3 times to Roger, ZAC, about the problems. Roger acknowledged the problems. It appears to me that my skins were manufactured during some sort of a change over and several pieces are miscut/punched.

4. I decided to just drill new holes for NR#4, and to plug the prepunched holes w/ 3/32" blind rivets.

5. The solution for NR#7 that I worked out in consultation with both Roger is:

- Remove (clecoed) NR#7.
- Get a left wing nose rib and drill it to attach to the flange at the end of the spar.
- The reversed flange of the left NR#7 will match with pilot holes inboard of the location possible with right NR#7.
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R nose skin, ribs  1, 2, 3

R nose skin, ribs 1, 2, 3

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R nose skin, rib 6

R nose skin, rib 6

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R nose skin, rib7

R nose skin, rib7

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