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Kupe's Zodiac 650B
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Date:  1-24-2014
Number of Hours:  1.50
Manual Reference:  6-B-6 & 7
Brief Description:  Firewall 2

Continued with the firewall today by adding three more structural reinforcements. The side braces run from the top stiffener down to the bottom stiffener and reinforce the location of the top and bottom engine mounts for each side. These were a standard match-drill session as the firewall itself has most of the rivet (pilot) holes already drillled out from the factory. The only additional work was fitting the top end of the side braces into the curved areas along the firewall flange (both ends) and the inside bend of the top stiffener ... nothing a pair of snips and a vixen file couldn't deal with.

Next was the center stiffener. Luckily, the good folks at Zenith have already drilled this out so all that was left for me to do was to cleco it into place!

Finally, I attached the gear gussets which connect the top stiffener (which houses the top of the nose gear) with the center stiffener and holds the top stiffener 90 degrees to the firewall. Again, the gusset flanges on the top stiffener end were pre-drilled to the top stiffener so all that remained was to square up the top stiffener, clamp the gussets to the center stiffener, and match drill through the holes in the gussets into the center stiffener.
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Center firewall stiffener and gear gussets clecoed into place.

Center firewall stiffener and gear gussets clecoed into place.

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Intersection of top stiffener, rear reinforcement and side brace - an upper engine mount will be here.

Intersection of top stiffener, rear reinforcement and side brace - an upper engine mount will be here.

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Front of firewall so far - top, side and center stiffeners with gussets.

Front of firewall so far - top, side and center stiffeners with gussets.

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