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Kupe's Zodiac 650B
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Date:  12-3-2013
Number of Hours:  2.00
Manual Reference:  6-W-8, 6-W-9
Brief Description:  Right Leading Edge Updrill, Wingtip Start

Got back to the leading edge skin this morning. Re-re-leveled the wing and re-re-checked the alignment of the 2 skins and main spar top flange one last time, then proceeded to updrill everything to final (A5) rivet size. I also drew out the rivet line for the "hidden" nose rib #4 which has no pilot holes drilled from the factory (it's outboard of the fuel tank which can be different sizes). Drilled it out then updrilled it to final (A4) rivet size. Nose skin all drilled out.

I checked the alignment of the fuel filler which was spot on again thanks to the handy tip of using a clear plexiglass template to mark the position of the hole (thanks homebuilthelp.com). All that's left for that is to open the hole up a few millimeters all around to let the beveled flange set in deeper into the opening - if you look closely at image 1 you might see the fuel cap sticking up above the skin. I drew a circle around the installed fuel cap to act as a guide when I widen the hole. That's what Dremels are for!

Lastly, I did a preliminary fitting of the wingtip only to find out that there was a small (30mm) bubble in the fiberglass just below the skin on the top edge which allowed the cured surface to break off. I'll bondo that up with Super Fil - a sort of light weight Bondo for aircraft. Otherwise, after some considerable wresting, I managed to get the wintip into place. I tried several methods to sliding the wintip flanges between skin, spars, channels, and sitffeners with little progress. Then all-of-a-sudden it slid into place. I have no idea what I was doing different at the time - maybe holding my tongue just right - but I did get it set where I wanted it.
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Leading edge all drilled out.

Leading edge all drilled out.

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Fuel filler hole - right on target.  Small adjustments needed to fit the flange better.

Fuel filler hole - right on target. Small adjustments needed to fit the flange better.

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Wingtip - first fitting.  Small damaged area barely visible on the top forward edge.

Wingtip - first fitting. Small damaged area barely visible on the top forward edge.

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