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Debo Cox - Zodiac 601 XL
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Date: 7-3-2007
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Number of Hours: 6.00
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Manual Reference: 6W
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Brief Description: Wing Dihedral and Attachment Drilling
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I couldn't put it off any longer. After months of fretting about drilling the wing attachment holes through the spars, I decided that in order to continue, it had to happen today. I spent a good deal of time getting the drill press and table set up and leveled to drill perfectly perpendicular holes. My new digital level helped a lot. I'd recommend getting one if you don't have one. $50 at Sears - worth every penny. Using the plans, I made careful measurements and drilled #30 pilot holes throught the outboard spar. On the outboard spars, it's fairly easy to put the holes where they need to be - that's why I drilled those first. Next, I drilled the top center hole in the center spar. Using a drill bit as an index pin, I placed the drilled outboard spar on top of the center spar and spot-marked where to drill (after careful measurements to ensure the correct dihedral). From there on, it's just drilling progressively bigger holes up to 13/64, then using a 5/16 hand reamer to ream the holes. The fit is perfect. The bolts fit tightly in the holes with no play, and they're exactly where they need to be. It took me 6 hours to drill and ream 12 holes, so I worked slowly and deliberately, making sure everything was perfectly level and correct before making any moves. I'm REALLY pleased that this job is over, and that it turned out so well. I could not have hoped for any better.
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Using bolts as registration pins
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Drilling the center spar
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