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Steve's CH750 Cruzer (N750SB)
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Date:  6-13-2017
Number of Hours:  5.50
Manual Reference:  
Brief Description:  Completed bungee pin relocation

Drilled out the existing channel rivets where the new reinforcing panel will go. I used a cutoff wheel to shorten a #20 drill bit and the frankendrill to get them out.

Measured and cut reinforcement panels from scrap .063" sheet metal. Finish trimmed and shaped to fit on outside of existing gear channel. Clamped the new channel reinforcements in place and used the frankendrill to backdrill from the inside of the channel through existing holes. Used the existing bungee holes to outline on cleco'd reinforcement, the current location of pin holes. Marked new center 3mm aft of existing center. Step drilled new bungee location on fabricated parts.

Taped over existing holes in channel and cleco'd new parts on top. Outlined the new hole outline on tape and removed cleco'd parts. Then followed multiple iterations of grinding to elongate the existing channel holes and clecoing the new parts to test fit the pin, followed by unclecoing and grinding again. Eventually, the pin went through the new pathway.

Cleaned up the fabricated parts and sanded smooth the elongated original bungee holes.

Since I had the Viking bungee, I did not originally flush rivet that part of the channel as I didn't think abrasion would be much of an issue. This time, I decided to go ahead and try to get it as flush as possible. I used a short large diameter drill bit to intentionally countersink from the inside of the channel. Since all my hand squeezer tips were dimpled by Zenith, I drilled a #40 hole in a washer sized piece of the .063 material and slipped it over the rivet shaft before using the hand riveter. Turned out that worked out well.

All that remained was to reassemble the steel bungee and strut. That went pretty quickly.
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Fabricated bungee pin side reinforcement parts

Fabricated bungee pin side reinforcement parts

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