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Zenith CruZer & Sonex Logs
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Date: 8-5-2008
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Number of Hours: 1.30
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Manual Reference: SNX-W08
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Brief Description: Root Wing Attach Assembly
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This was not a good night, construction-wise.
Had to do things a bit out-of-order since I have the prebuilt spars and the machined angle components. The angle was pilot-drilled for the attachment points to the spar, and the spar was drilled out to 3/16".
Went to mount the attachment block to the angle, and was drilling the pilot holes for the 1/4" attachment bolts which hold the block to the angle. Then, after I finished the 2nd pilot hole, I noticed that I drilled the holes on the wrong side of the block.
So I had to fabricate a new block.
Proceeded with mounting the block, and then mounting the assembly to the spar. All went well until I came to the inner mounting holes, which require a countersunk machine screw on the forward side of the spar in order to allow the spars to mate. The plans say I should dimple the main spar web and countersink the center web (much thicker). Can't do that because the spars are pre-assembled. Kerry at Sonex allegedly told another builder to just go ahead and countersink. So I did, too.
Looked pretty good until I tightened the machine screw. It pulled thru the main spar web such that it's below the surface of the spar web. Unknown at this time (10 PM) if that's acceptable or if I ruined the spar, or if I can put a new hole next to the old one. I'm thinking that it's probably acceptable, because there's no way to countersink that hole and have anything left of the main web with which to support the screw. We'll see what Sonex says.....
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Ooops; drilled pilot holes on the wrong side of the block.
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Over-Countersunk screw on forward side of Right wing spar. Depth is limited to main web. Looks deeper.
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