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Kupe's Zodiac 650B
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Date:  6-20-2014
Number of Hours:  2.00
Manual Reference:  6-C-1
Brief Description:  Forward Top Skin 3

Continued work on the forward top skin. I finally have determined how I will proceed. The top skin attaches to the top of the firewall and the top of the instrument panel and connects to the side panels that house the canopy rail. I want to make this piece removable so that I can gain access to the avionics bay (in front of the instrument panel) without having to stand on my head in the seats! So here is the plan:

1. Install countersunk nut plates along the top of the firewall & instrument panel and along both side panels.
2. Dimple the top skin at each of the attachment holes to keep the skin flush when attached. This was a challenge since the distance between the edge of the top skin and the holes in the skin exceeded the reach of my dimpler. My simple solution is in image 2.
3. Attach the skin using #8 machine screws with Tinnerman washers.

The plan is fine except for the additional skin flap that reaches all the way to the forward skin on the fuselage (lower right corner of image 3). Since that section attaches to the upper longeron, it's really too thick to use a nut plate and impossible to dimple. I have a plan for that section which I'm still working out...
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Dimpled holes with countersunk nut plates underneath them.

Dimpled holes with countersunk nut plates underneath them.

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Dimpling the skin with my jury-rigged dimpler since the edge distance was so large.

Dimpling the skin with my jury-rigged dimpler since the edge distance was so large.

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Completed so far - still working on a solution to the lower-right skin flap.

Completed so far - still working on a solution to the lower-right skin flap.

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