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Zenith CruZer & Sonex Logs
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Date: 8-28-2011
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Number of Hours: 2.30
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Manual Reference: SNX-F02
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Brief Description: Part I - Re-drill Wing Attach Blocks
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Same words as other post this day; just wanted to show more pictures.
Well, today was re-drill day for the wing attach blocks. For a refresher, when I rigged the wings on 4 June, I wallowed-out the aft wing attach blocks. These are the ones on the right wing, since it mounts further back in the fuselage. In the pics below, the left wing spar is the one facing the camera.
Since the left wing attach blocks were still good, I obtained two sections of 3/8" OD tube - one to act as a guide for a 1/4" drill, the other with a 5/16" ID to act as a guide for a 5/16" drill. With my son, we positioned the wings on saw horses in the front yard. Got a lot of strange looks from passers-by! Inserted the 3 alignment pins in the wings and clamped the two spars together.
I inserted the drill guide in the forward attach blocks and drilled the initial 1/4" hole thru the attach blocks. This was the most difficult part of the entire operation as the attach blocks didn't have any pilot holes in them - didn't want a miss-drilled hole "steering" the drill bit. Had to stop and back-out the drill quite a bit to clear chips. I also had to re-make two shorter drill guides as the originals kept the drill bit from going all the way through both blocks.
Once the 1/4" "pilot" hole was complete, I replaced the 1/4" ID guide with the 5/16" guide and up-drilled to 5/16". Then I remove the guide and carefully up-drilled to 3/8" to avoid wallowing the previously good holes in the foreward attach blocks. Cleaned it all up and I was complete!
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3/8" OD tube; left is 1/4" ID, right is 5/16" OD
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Clamped together; note alignment pins
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Overall View
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