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Kupe's Zodiac 650B
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Date:  4-18-2015
Number of Hours:  2.00
Manual Reference:  
Brief Description:  Nosegear Steel Bungee

Received my steel bungee kit from Viking Aircraft Engines and decided to install it today. The steel bungee is a replacement for the rubber bungee that comes with the Zenith kit. While the rubber bungee is light weight and functional, it initially starts out with considerable tension making it difficult to turn the aircraft on the ground and make fine rudder corrections in the air. It also wears out over time requiring continual inspections. Finally, replacement of the rubber bungee takes significant effort and specialized tools and is made even more difficult with the engine in place.

The steel bungee, conversely, is infinitely adjustable to account for different engine weights and personal preference of the pilot. Since it's made of aluminum and steel it should last the life of the aircraft. If it should break, reinstallation is much less challenging requiring only common tools.

The first step to installing the steel bungee is to disassemble it into it's 5 component parts (top spring saddle, bottom spring saddle, spring, and L/R steel straps) and paint the steel spring with rust inhibiting paint. While it is disassembled, mating the top and bottom spring saddles together (normally the spring is between them) makes a good template for marking the 2 holes needed for the L/R steel straps where they go through the top firewall stiffener. Once I marked and drilled those out, I cleaned up the holes and test fit the straps.

Next, I removed the pin (a 5/8" tube running through the verticle firewall stiffener) to add two additional cotter holes to it and replaced it back through verticle stiffener and the 2 steel straps - the new cotter holes being used to stabilize the steel straps on the pin.

I left the rest for tomorrow after the paint on the steel spring has a chance to dry.
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The steel bungee shock absorber including top/bottom saddles, L/R straps and spring.

The steel bungee shock absorber including top/bottom saddles, L/R straps and spring.

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Old rubber shock absorber after cutting - the only way to safely remove it.

Old rubber shock absorber after cutting - the only way to safely remove it.

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Initial installation of L/R side straps.

Initial installation of L/R side straps.

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