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Zenith CruZer & Sonex Logs
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Date: 9-20-2008
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Number of Hours: 7.70
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Manual Reference: SNX-W17
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Brief Description: Root Rib & Aileron Bellcrank Parts
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Long day; funny, doesn't seem like much got done.
I was a bit concerned about getting the root rib done due to comments made by other builders on their websites. Not too, bad, but you're supposed to ensure that alignments are checked, the wing is square, etc.
Started off making some detail parts, since I had to cut some stock anyway for the SNX-W17 scratch-built gussets. Cut 8 blanks for root rib gussets (4 per side). Then, cut 2 each forward and aft vertical channels for the aileron bellcrank support that fits on rib #9. These supports were SNX-W21-13 / -14. Messed up on the forward channels. Read the plans too fast; saw that it said to make the channels from 7.5" stock. So I made 4 of them. Then I saw on the plans that two of 'em were 7.75" long. Drat. Scrapped the two. Fortunately, I had some scrap channel from when I was working on the elevator, so that was not a problem. Also cut 8 SNX-W21-09 clips that are used to secure the channels to the upper/lower aft skins.
Fabricated 4 unique gussets for the root rib; took about 15-20 minutes per gusset.
Had to trim the rear edge off the foward root rib by 3/8", and trimmed the aft rib by 3/8" on the main spar side, and 9/16" on the aft spar side. Trial fit the root rib onto the brackets. Had to re-do the spar cap clearance cuts twice to give enough room to clear the caps.
Fabricated a jig that several builders have had success with using - this helps to lock in the positioning of the aft spar in relation to wing station 0,0, ensuring the wing is aligned properly.
Removed ribs 1 & 2 to allow enough room to drill a few holes for cleco's in the root rib attachment brackets. Then removed the brackets, drilled all holes, up-drilled them to #30, and called it a night.
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