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Debo Cox - Zodiac 601 XL
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Date:  8-1-2008
Number of Hours:  4.00
Manual Reference:  6B
Brief Description:  Fuselage Side Skins

After carefully leveling and tweaking for a long time, I was finally satisfied enough to start attaching the side skins. I really took my time on this one and didn't drill anything until I was totally ready to commit to it. The only problem I had was with the triangular floor gusset. Intuitively, the gusset fits between the gear channel and the center spar, but mine (made perfectly to plans I might add) were about 8mm too short. Being the kinda guy I am this grated on me, so I made a new set 8mm longer - perfect fit. The next problem with it was that my set of pre-drilled side skin holes seemed a little high - putting the drilled holes in the gusset lower than I would have liked. I tweaked and fiddled - making yet another gusset in the process until I got the line out of the bend radius of the part. If there's one drawback to pre-drilled skins, it's this. Sometimes it's almost a physical impossibility to make something fit together like they're drilled without violating some type of rule.
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Side skins going into place

Side skins going into place

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My re-made floor gusset

My re-made floor gusset

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