Tried to rivet spar cap extrusion, 6-ZU-1-1, to the main spar. The rivets sent with the upgrade kit were too short and didn't quite extend far enough through the spar cap. They extended about 1d and not 1.5d as they should have. They were what was specified in the drawings. I called Quality Sport Planes in Cloverdale to discuss the situation with Doug. He noticeds the same thing and was unsure what to do. I called Zenith in Mexico, MO, and talked to Roger. He was just leaving but would check in to it and get back with me. I called Doug and let him know. Doug was going to set a couple rivets and see what they looked like and call me back. Doug never called back. I ordered more (longer) rivets from Aircraft Spruce. The rivets needed are two differnt lengths of about 6-11 and 6-15. They sent 6-10 and 6-14. I took some of the AN6-14 rivets and cut them off to the correct length. Chris helped me set those rivets. I'll have to wait for the rivets to come from Aircraft Spruce to finish the rivet job.
I drilled out rivets on the bottom spar cap to install the wing spar doubler at the root end. That is part 6-ZU-1-2. Figured out how that will go on. Realized I would need 0.3125 reamer to get the main spar attach bolt holes sized correctly.
