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Zenith CruZer & Sonex Logs
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Date:  1-22-2019
Number of Hours:  1.80
Manual Reference:  C75-FA-7
Brief Description:  Left gear mount, left cabin frame reinforcement

Figured I'd do a few things to kill some time today, and it turned into longer time than I thought it would....

I had previously drilled the pilot holes in the forward steel bracket that connects the cabin frame to the fwd fuselage longeron. Clamped in position and drilled all 10 holes (5 each leg) to #40, then updrilled to #30, then finally to #20 for A5 rivets.

Next, although I had previously installed the right gear mount weldment, I really hadn't touched the left side. Cleco'd into position, then up-drilled existing holes to 3/16" to accept AN3 bolts - 11 total, plus one 1/4" bolt. Several of the holes did not exist in the weldment, so had to back-drill from the back side of the fuselage side into the steel. Drilled a few seconds in each place, then removed the mount and finished drilling on the bench to get better leverage.

Lastly, fabricated a piece of L-angle to reinforce the junction of the gear channel to the fuselage side skin. As with the right side, the factory-drilled holes were a bit too close to the edge of the Zenith-supplied L-angle, so I used scrap pieces from a prior build to ensure enough "meat" was present in the edge distances. Pilot drilled and back-drilled thru the skin with #30 holes. From the mount side, I used a #20 drill to up-drill the holes. When I removed the L to check, most of the holes were elongated, so I had to re-make another new piece of angle. All holes now round!
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in the process of installation; more holes to drill

in the process of installation; more holes to drill

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Holes drilled using brace as template

Holes drilled using brace as template

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trashed L-angle for gear channel-to-fuse side

trashed L-angle for gear channel-to-fuse side

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