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Zenith CruZer & Sonex Logs
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Date: 10-17-2008
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Number of Hours: 3.90
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Manual Reference: SNX-W07
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Brief Description: Right Wing Bottom Aft Skin Fitting
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Lot's of work; mostly just tedious. No major components done. Just lots of holes. Really not looking forward to deburring all of these....
Only had the aft skin leading edge to finish drilling/cleco'ing to the main spar. Last night, just put in 1 cleco for each rib. Theres just about 100 holes to be drilled. Thick aluminum; took quite some time.
Even with the new cleco's, and even leaving every other hole empty, was still getting low on cleco's. Decided to up-drill all of the rib holes to #30 and use the 1/8" cleco's. Sonex says you only need about 200 of each type of cleco, but that's really stretching it.
Once I had all of the skin cleco'd as I wanted it, stood the assy on edge using saw horses. Did this to drill/cleco the aileron bellcrank stiffener. Some folks have advised not mounting the small clips to the vertical stiffeners until you have the skin on in order to get the spacing done. When I was setting up rib #9 with all of the related parts, I had a curved piece of sheet aluminum that I used to help establish the placement of the clips. I ended up riveting them to the stiffeners, and the stiffeners to the rib at the time I completed the rib. This worked out well; the clips were sitting nice and flush against the skin.
After that, we put the assy back onto the bench, this time with the skin down, in order to facilitate the fitment of the lower aft skin. This is a bit trickier - you have to re-level the wing to ensure no twist, and reverify the squareness. The jig I made up kept everything lock-tight square. The other issue is that you cannot yet rivet the upper aft skin into position, so you have all these cleco's sticking out - and, ideally, you don't want to rest the whole assembly using only the cleco's for support. Had to cut some wood spacer blocks to raise it off the bench just a bit to take off the pressure, then re-level the wing. Then drew the blue centerlines on all the ribs.
Initial "just laying the skin in place" put a smile on my face. All Blue Lines were visible.
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Ribs Up-Drilled to #30
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Just looks pretty sitting there
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Aileron Bellcrank Clips
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