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Kupe's Zodiac 650B
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Date:  1-30-2014
Number of Hours:  1.50
Manual Reference:  6-B-10
Brief Description:  Center Spar Drill Out

Attached the center wing spar to the cabin floor today. In addition to holding the main spars of the left and right wings, the center spar acts as the forward part of the pilot/passenger seats - one's legs drape over the spar at the knees. This installation involved:

1. some very careful measurement of the spar centerline.
2. marking and drilling out a rivet line on the forward lower flange of the spar precisely 55 mm forward of the centerline of the aft lower flange of the spar.
3. sighting a rivet line on the bottom of the aft spar lower flange through a pre-drilled rivet line in the cabin floor.
4. Drilling up from underneath the cabin floor through the line in the aft flange of the center spar.
5. Drilling down through the already drilled rivet line on the forward flange through the cabin floor.

Other than a lot of blood rushing to my head trying to drill while upside down through the cabin floor, the job was pretty straight forward. However, it was tedious drilling through the cabin floor via the forward flange rivet line as the spacing is so tight (with the spar tilted 7 degrees forward) I had to use my trusty Tight-Fit Angle Drill attachment which has to be treated with kid gloves or the gears in it strip.
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Center spar clecoed to the cabin floor as seen from behind looking forward.

Center spar clecoed to the cabin floor as seen from behind looking forward.

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Front side view of the attached center spar.

Front side view of the attached center spar.

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The Tight-Fit angle drill attachment.

The Tight-Fit angle drill attachment.

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