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Zenith CruZer & Sonex Logs
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Date: 12-3-2011
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Number of Hours: 4.20
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Manual Reference: n/a
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Brief Description: WS Bow / Battery / Rivet Panel
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Good day.
Started off by installing a set of battery charger connections. I purchased the Odyssey charger due to the special charge profile required by the PC625 battery. Up until now, I just connected the normal clips to the battery. The charger came with a permanent connection lead that can be installed on the batter such that the clips are not required. Installed and tied-off the lead.
Next, I installed nutplates for the lower forward windshield bow. These are spec'd to be installed with normal AN3 nuts, but since it's somewhat of a hassle to reach these fwd bolts with the windshield installed, I decided to go with nutplates. I installed "end" type nutplates.
Lastly, I riveted the panel in place. This wasn't a simple pop-pop-pop with the rivet gun, as the left corner pieces had the throttle/mixture cables in the way. I also had to remove the aft windshield bow to gain clearance for the rivet gun. Compounding matters was that the mixture cable retention nut presses right up on the underside of the panel lower crossmember, so the rivet holes were not perfectly lined up. Used an awl to move things into place and installed 8 rivets. The right side was much easier, relatively, since there were no controls in the way. Still had to remove the WS bow....
Lastly, hooked up the compressor and installed the remaining easy-access rivets in the panel top and bottom. Frustration in that 2-3 rivets on each side slope could not be installed with the HF riveter due to the WS bow being in the way. I had to manually pull the rivets. One entire mandrel fell thru the rivet and onto the lower panel crossmember. I could not feel it or retrieve it. All I could think of was that mandrel bouncing around in turbulence and shorting the switches. After cleaning everything up and putting the tools away, I tried one more time. Finally felt it, but could not grab it. Put some tape on my finger sticky-side out and was able to retrieve it. Feeling much better about it now.
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Installed battery connector cable
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Nutplates installed lower sides of cowl bow
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All rivets installed in the panel
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