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Jims Web Site
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Date: 4-22-2011
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Number of Hours: 3.90
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Manual Reference: 6ZU1-4
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Brief Description: Added stiffners to upper skin
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The Zenith drawings call out stiffners to be added under the upper and lower wing skins. The trick, obviously, is to get them cut to the correct length, and placed in the correct position.
1) Clecoed leading edge area of wing skin, so position would be held.
2) Marked wing rib locations on upper surface.
3) Measured distance from the wing spar to the stiffner locations, and marked on either end of the wing skin.
4) Snapped chalk line, to mark location of stiffners.
5) Placed "L" angle material along line, and marked length to be cut, for 5 separate pieces of angle.
6) Cut and deburred each angle, marking each piece with its intended location.
7) Placed additional clecos in skin and ribs, to assure stiffness.
8) Drilled #40 pilot hole in stiffners, centered on stiffner, and 15 mm from each end.
9) Taped stiffners into position along chalk line.
10) Back drilled one end hole with #40 bit, clecoed, and drilled other end hole.
11) Removed clecoes, stiffners, and tape.
12) Cleaned chalk line and dust from skin.
13) For each stiffer location, used rivet gauge to establish ~100 mm pitch.
14) Punched rivet locations.
15) Removed clecos from back edge of skin, to approx two rivet locations ahead of area where stiffners were to be added.
16) Supervised by Halloween, slipped stiffners under skin, and caught end holes with clecos.
17) Reinstalled clecos in trailing edge and wing ribs.
18) Drilled punched locations with #40 bit, clecoing as holes were added.
19) One by one, removed clecoes, opened holes with #30 bit, and installed larger clecos.
20) Removed clecos, allowing stiffners to drop to bottom skin, in preparation for stiffner deburring and priming.
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Measuring "L" angles for length
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Slipping "L" angles into position
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Back drilling "L" angles
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