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Kupe's Zodiac 650B
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Date:  10-3-2017
Number of Hours:  4.00
Manual Reference:  
Brief Description:  Right Wing Install Prep 4

Last task before final installation of the right wing - the right wing root fillet. The fillet provided by Zenith is a standard piece of rubber trim for a 90 degree join point. What's hidden from the picture below is the other small (inside) flange that, along with the flange you see in the picture running down the top of the wing surface, forms the bottom side of the slot the wing skin slides into. The trick, then, is to affix those two flanges of the trim onto the outside and inside of the wing skin so that when the wing is fully inserted, the verticle part of the trim fits snugly against the fuselage. Sounds easy, doesn't it? It is, except when it's not.

The plans mention that the lower (inside) flange will need to be trimmed where it crosses over the wing spar. This makes sense because the top skin is riveted down tightly at that point so there's no way to work the inside flange under the wing skin. What is not mentioned in the plans is how narrow the distance is between the inboard wing rib and the edge of the wing skin from about 100 mm forward of the rear channel to about 200 mm aft of the main spar. Without trimming this portion of the inside flange, the wing skin doesn't seat fully into the trim slot which means the wing does not seat fully into the fuselage. Once I figured this out, it was an easy matter of tracing the relationship of the wingskin to inboard wing rib along an L-angle which I then transferred to the rubber trim piece. After that, the wing slipped into place, so I finished it off by gluing the rubber wing fillet in place using Gorilla Glue.
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Wing root fillet diagram showing outside and inside flanges plus the part that snugs to the fuselage.

Wing root fillet diagram showing outside and inside flanges plus the part that snugs to the fuselage.

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Right wing root with rubber fillet being installed.

Right wing root with rubber fillet being installed.

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Aft edge of right wing by fuselage. Attach plate and rear channel touch.

Aft edge of right wing by fuselage. Attach plate and rear channel touch.

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