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Larry Winger's 601XL Project
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Date: 2-26-2011
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Number of Hours: 5.50
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Manual Reference:
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Brief Description: Installed new center spar rear uprights
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I've been slowed down by work issues and reinstallation woes. When I tried to line up my old rear uprights with the modified center spar, the geometry was off because of the addition of the side doublers. I checked with ZAC and the only real solution was to replace the rear uprights. In addition to the work of it, I faced the prospect of having to reset the angle of my center spar which I really didn't want to do. My work-around was simple but effective. Using a strip of scrap aluminum, I made a template of the hole pattern from the old uprights, I then transferred this to the new parts, placing the face of each upright precisely where the old part had been. For some reason, three of the four top/bottom doublers on the center spar were long enough to interfere with the rear uprights, so I had to carefully remove the extra length while the doublers remained attached. Not easy to do without nicking the web beneath, but I was successful. Then I reinstalled the center spar and uprights, pulled the spar snug to the face of the uprights and drilled through to cleco them together. Once they were again removed, I was able to center punch the 5/16" bolt holes and then dirilled each hole up to just under 5/16". Because the part had been clecoed, that allowed me to put the parts back together and ream the holes up to the final size. My last task of the night was to put everything back in the plane so it is ready for installation of the front uprights. This step had me scratching my head over the last few weeks, but it went quite well -- just time consuming. I feel good that the center spar angle is exactly as it was before the modifications.
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Center spar back in place with new rear uprights
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Rear uprights clecoed to spar web
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Closer look at clecoed upright with 5/16' reamed holes for bolts
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