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Zenith CruZer & Sonex Logs
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Date:  4-28-2018
Number of Hours:  2.80
Manual Reference:  C75-WA-3
Brief Description:  More debur, flaperon brackets, reassemble

A lot of tedium today.

Next to the very edge of the nose ribs, there are #40 piloted holes in the skin that must be drilled thru the nose rib; all other rib & skins came pre-drilled to #20. Drilled out the lower edge of these (did the uppers the other day), and deburred both the top and bottom holes.

With the flaperon brackets cleco'd, had to backdrill thru the L-angles at the base of each bracket. The skins are predrilled to #40, but the L-angles are not; drilled from underneath the wing, which given mobility issues was not the easiest. Once drilled to #40, then updrilled to #30. Riveted the flaperon brackets to the rear of 4 aft ribs. Then attached the L-angle at the base of each. Standard practice calls for the rivet head to rest on the thinner metal, but in the fuel tank bay, the rivets protruding thru the thicker bracket would interfere with the tank. These rivets are intentionally driven "backwards" as per Zenith direction.

Spent a lot of time on re-positioning the wing, checking level, and cleaning for the debur and drilling debris. Can't have FOD bouncing around the inside of the wing! Re-installed aft skin and cleco'd every other hole in the aft, nose, and main spar in preparation for riveting.
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Flaperon bracket riveted

Flaperon bracket riveted

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Fuel tank bay bracket riveted - note rivets

Fuel tank bay bracket riveted - note rivets

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Ready for rivets

Ready for rivets

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