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Debo Cox - Zodiac 601 XL
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Date:  3-22-2006
Number of Hours:  5.00
Manual Reference:  N/A
Brief Description:  Completed Bending Brake

Finished up the bending brake today (minus the paint job). I've been studying this project for a long time - scouring the internet for plans - even buying a set or two. I decided that the Zenith brake was a good balance of ease of construction compared to versatility. With limited metal fabrication knowledge, I was able to make all of the parts and even weld it together. One note, don't think you're just gonna whip this thing out in a flash. I learned that working with steel takes patience to get things right. I'm very happy with the results. Everything fits together perfectly and it works like a charm. I experimented with some .016 aluminum bends to get the results the plans call for. What I learned is this - whatever the plans call for as a flange, add 2mm to the measurement, and that's your bend line. Sight the line from straight above it, and line it up with the edge of the clamp. I realize that the 2mm measurement might change a little with different thicknesses, but for .016, I've got it dialed in. Big hurdle cleared today. I'm about to start scratchbuilding my own parts. I'm really glad that I bought the rudder kit from Zenith so I'd know what good parts are supposed to look like. Even my test ribs look as good as anything that came from the factory. I'm encouraged that I'll be able to achieve the high degree of craftsmanship that I'm looking for.
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Completed brake awaiting purple paint job. Susan picked the color. Purple is her favorite.

Completed brake awaiting purple paint job. Susan picked the color. Purple is her favorite.

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Hinge detail.

Hinge detail.

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Completed test parts. I'd use these for the aircraft, but I bent (and re-bent) them.

Completed test parts. I'd use these for the aircraft, but I bent (and re-bent) them.

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