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Steve's CH750 Cruzer (N750SB)
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Date:  12-28-2017
Number of Hours:  2.25
Manual Reference:  
Brief Description:  Started replacing pilot side wing tip (again)

These plastic wing tips are the bane of my build. I fully messed up the 1st set. The 2nd set developed cracks after installation and Roger sent a new set made with new material. Hopefully the 3rd time is the charm. This time around a couple of things are different. First, the wings are on the plane rather than in the wing cradle, so I may get a better fit for any minor differences induced by wing orientation stresses. Second, I took a close look at other Cruzers at Zenith Open Hangar days in Sept. and noticed a large range in how the tips fit on each aircraft. Some were fit deep into the wing, while others had a good amount extending past the skin. It was not necessarily consistent between pilot and passenger sides. Leading edge fit also varied considerably and these planes are not falling out of the sky. I realize some of my issues may be from trying too hard to get the perfect fit.

Started by drilling out the wingtip rivets and removing the tip parts and wingtip strobe. Then I trimmed the extra filler off the plastic parts. Used shears to get it close then switched to the grinding/scotchbrite wheel to retain the maximum amount of part flange without any gouges/nicks that could tear. Then I test fit each half separately, making some filing/rounding tweaks to the aluminum structure to help prevent gouges from the edges.
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Fitting wing tip

Fitting wing tip

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