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Larry Winger's 601XL Project
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Date: 10-3-2006
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Number of Hours: 3.00
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Manual Reference:
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Brief Description: Made attachment doublers and drilled front spar
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After giving this much thought, I decided to remake the front attachment doublers to insure a good fit with the front spar and the front spar attachments. Next I pulled out the photo assembly guide and walked step-by-step through the drilling and assembly process for the front spar. By the time I needed to quit, I had completed everything but the reattachment of the center ribs and the L angles on the ends of the spar. That should take no more than 90 minutes tomorrow, then on to deburring the front spar and priming. More rivets (nearly 10,000 to be precise) should arrive on Thursday. By the way, I did hear back from Zenith today and Caleb gave me a solution I could have used. It would have required remaking the front spar attachments, but making the mating flange (to the spar) twice as wide as normal. in the additional width I would have put another four rivets, far exceeding the strength needed. Additionally, I would have been required to cut the flange width back to normal right before the intersection with the skin. In this way, the part protruding from the skin would be standard size, while the upper portion would be wider to accomodate more support from the eight-rivet pattern he authorized. That fix might have taken 90 minutes (as most), instead of the 5 hours for a complete front spar redo. At this early stage, I'm still enough of an idealist that I'd like to avoid compromises if at all possible. If I do something like this again, and a factory-approved solution will save me 5 hours, don't be surprised if I change my tune!
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The reassembled rear spar ready to mate up with the soon-to-be-completed front spar
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5 holes where there used to be 4. The old spar on the left for reference.
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