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Zenith CruZer & Sonex Logs
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Date:  3-17-2018
Number of Hours:  2.30
Manual Reference:  C75-WA-1
Brief Description:  Add'l Skeleton Detail parts

Put some decent time in just doing another bunch of piddling work.

As I mentioned yesterday, the pre-attachment of the spar root angle complicated things with the root nose rib. I spent quite a bit of time "finessing" this area. Task consisted of bending the pre-fab angle down out of the way so it resides under the root nose rib as in pic 2 below. This involved trimming a bit of the root angle to facilitate a smooth transition from the rear root rib to the slope of the nose rib. This took quite a bit of time and error. That allowed the nose rib to sit flush to the spar. Until I saw the front side of it, that is. To get the spar root angle to follow a curve, fluting pliers are used to shrink the material, pulling it into a curve. This creates flutes on the backside of the flange, which of course pushed the nose rib away from the spar. Again, more trial and error bending the nose rib flange so it clears the flute yet still remains flush with the spar at the rivet line.

Next, I trimmed the root rib splice piece shown in pic 2. This just proivdes added stiffness and rigidity to the two root rib sections at the wing-to-fuselage attach fitting.

No pics, but also spent a lot of time getting the rear flange of the root rib to fit the rear spar channel correctly; had to trim some of the flange material and "adjust" it by bending a bit where the flange fits under the spar flanges.

Lastly, measured, marked, and pilot drilled 270 and 50mm L-angles that attach to the main and rear spar to allow a mounting surface for the fiberglas wingtips. One pilot hole is drilled, then the other holes are back-drilled thru the two spar ends. These are updrilled to #30/A4 rivet size.

At this point, I believe ALL skeleton work is done, and riveting will be the last step before skins are mounted.
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Fiberglass tip attach angle

Fiberglass tip attach angle

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Root Nose Rib rework

Root Nose Rib rework

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more nose rib work

more nose rib work

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