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Zenith CruZer & Sonex Logs
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Date: 10-26-2009
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Number of Hours: 1.50
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Manual Reference: SNX-P31, SNX-C07
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Brief Description: Motor Mount Drilling / Spar Carry Thru Hole
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Finally got back in the saddle on the airplane. Work has really been a struggle the past week; late nights - as in VERY late nights, weekend, etc. Then, when I was off yesterday (Sunday) I had a full day of catch-up type stuff - errands, yardwork, etc.
So tonight I finished drilling the motor mount to the fuselage. Last week I had drilled the lower mounts to the fuse (remember, the fuselage is inverted at this point). I wasn't 100% satisfied with the shims I had for the upper mounts, so I took some time, made some additional shims, and re-combined some of the thinner stock to get a nice fit.
Once in place, I pilot drilled (1/8") the upper mounts. Then, went over 6 of the 8 holes (2 per corner) and took them to 3/16". They need to go to 1/4" for the final hardware install, but I don't have 1/4" cleco's at this point. I did not want to do the nefarious lower holes because the wingnut cleco's I have are too long - they would have interfered with the landing gear tube that is part of the motormount. So I left these at 1/8" for now. Checking things out (see pic 2 below) I think I have just a tad more room than some builders, so it may not be too much of a struggle to get the nuts in there. Some builders have used low-profile nuts here, and some have had to cut down the machine screw portion as well.
I then experimented on some scrap stock with the hole saws I purchased to make the control stick holes in the seat pan. Each stick has a triangle hole with one end formed by a 4.5" hole, and the base of the triangle formed by two 3" holes. The saw cut better than I thought in my hand drill, so that is satisfying.
Lastly I cut the 1.75" center hole in the rear spar carry thru stock that I had done earlier.
It's amazing how time flies by. 1.5 hrs to drill 10 holes (4 pilot, 6 updrilled) and a 1.75" hole.
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Mount All Drilled / Updrilled to 3/16" (Final size 1/4")
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Tight Quarters for Lower Hardware
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1.75" Hole Drilled in Rear Spar Carry-Thru
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