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Paul's Zenith 601-XL
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Date:  5-2-2008
Number of Hours:  3.00
Manual Reference:  
Brief Description:  Made new front fuse sides and drilled them in plac

After much back and forth with Zenith on how to get the pre-drilled fuse sides to line up, I decided it was best to just make new ones without the mis-drilled lower line of holes. I drove up to Midland to the Zenair factory and picked up a 4 x 12 ft piece of 0.025 skin (the only size they had). While there I got to see the "new 601" in prototype that has a more raked rudder, split canopy with the front part fixed, and a much improved canopy locking system.

I used the old sides as a template and backdrilled the new sides. I then mounted the new sides on the fuselage and marked the front and rear spars and the gear channel. Everything was cutout and remounted to the fuse.
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Used old fuse sides to make new ones (except the bottom rivet line was left off

Used old fuse sides to make new ones (except the bottom rivet line was left off

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New side hung.

New side hung.

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Cutout for gear and spars made

Cutout for gear and spars made

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