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Zenith CruZer & Sonex Logs
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Date: 4-24-2010
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Number of Hours: 3.70
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Manual Reference: SNX-T01/-C01
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Brief Description: Install Elevator Rod / Install Rudder Cables
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A lot of work, lots of tedium.
Installed hinge pin cotter pins on the inner sides of the elevator. Prior to installing the horizontal stab to the fuselage, the elevators would swing more then 25 degrees, ripping the heads off any cotter pin I had installed. Now that everything is permanent, went ahead to install.
Determined where I was going to drill holes for the rudder hinge pin cotter pins. Prior to drilling I remembered that I had to install the elevator push rod before installing the rudder. Installed the pushrod and bolted it to the elevator control horn, and that's where the fun started. The elevator would not make the full swing up or down.
Noticed that in pic 1 below, the rounded arch thru which the elevator rod passes was hitting the rod when it was moved both fore and aft. Since I had both the horiz and vert tails installed, this was a real pain to re-shape. Used a manual half-round file, a carbide cutter in my Dremel, a sanding drum in the dremel, and a cutoff disk to do all the shaping. This was tedious and time consuming, with lots of stops to check the fit, cut some more, etc.
Also noticed the aft angle at the very rear of the fuselage was also hitting the elevator rod. I previously had to notch that to accomodate the elevator control horn, but neglected to notch it wide enough to accomodate the added width with the push rod installed. As I stated earlier, if the vertical stab was off the fuselage, it would have been no big deal to reshape this. Tight quarters and odd angles just added to the tedium
I then installed the rudder cables thru the bushings in the fuselage. You cannot fit the centers of the fairleads until the cables are in place. Working in limited areas, under the fuselage, with spring clips that had far more tenacity than I, was very painful and frustrating. Finally got all 4 installed.
Lastly, cleco'd the elevator trim tab to the elevator. I had left this off the elevator, since I had to order CCP-41 rivets as the -42's were too long.
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Elevator Pushrod / Reworked Angle
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Elevator Trim Tab
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