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Zenith CruZer & Sonex Logs
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Date: 11-28-2011
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Number of Hours: 1.80
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Manual Reference: n/a
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Brief Description: Finish Wing Wiring / Trim Doubler
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First step of the day was to sand and prime the left wingtip assembly. I had previously experimented with this tip to determine the color I wanted to use. I settled on Rustoleum Wheel Paint - this is designed for aluminum alloy wheels, and has a medium metalflake component to it. It also seems quite durable. Will still clear-coat it when finished, though.
Unfortunately, after I primed it, I noticed a few areas where the underlying paint started to lift when the primer was applied - more like a crazing. After it dried a few hours, I sanded with 400 grit paper (paint was obviously not fully hard yet), and it seemed to smooth out enough that I'll try another coat of primer on it tomorrow to see if that fixed it or not. If so, will then apply first color coat.
Next, I just had to finish the fuselage end of the left wing wiring after mounting the strobe units last Friday. I previously ran vinyl water tubing thru the forward rib forward holes. It was obvious, however, during wing rigging that this spot would be occluded by the fuselage side wall. The opening in the fuselage is only the size of the two rib lightening holes. On the right wing, I just made up a bracket for the wires and pitot/static. However, on the left side, the flap and brake levers partially occlude the opening. I was concerned that if I affixed a bracket to the fwd edge of the rib that I could not get my hand in there to attach the flap control rod. I decided to fasten the wire harness to the first bay of the wing, wrap the wires in protective sleeving, and let it hang free. There will not be a large amount of excess wire, so this should not be an issue.
Lastly, I trimmed each wing's doubler in order to provide a 1/16" gap between the wing and fuselage. Protected the spar with scrap stock and used the vixen file to trim it, then followed-up with ScotchBrite to finish smoothing it out.
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Wing, Right Side Up, showing wire orientatlion
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Wing, Upside Down, showing routing of wire
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Red Mark = area to trim on wing doubler
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