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Zenith CruZer & Sonex Logs
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Date: 2-15-2009
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Number of Hours: 3.60
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Manual Reference: SNX-W03
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Brief Description: Completed Left Aileron Subassemblies
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Riveted the left aileron drive plate/rib subassembly (not pictured).
Riveted channel subassembly SNX-W04-09 together (not pictured).
Positioned and secured the two cleco'd halves of the counterbalance subassembly in order to accurately position the SNX-W04-09 channel subassembly that closes the gap in the edge of the aileron where the counterbalance protrudes.
First positioned and secured the channel to one of the rib/bracket halves using visegrip clamps. Drilled pilot holes and cleco'd. Next, positioned the two rib/bracket halves together on a flat surface of the workbench to ensure the halves were level and square. Clamped this in position and pilot-drilled the other rib/bracket to the channel assembly. Then up-drilled to #30 all holes.
Removed, deburred all pieces, and riveted together. Due to the proximity of the lower rivets to the flange of the rib, had to bend the rivets slightly and use a beveled trim piece to allow the nose of the riveter to pull the rivet accurately. Had one bad rivet (failed the fingernail test) that had to be replaced.
Also had to replace 3 other rivets due to my own negligence. The rib-to-bracket rivets are CCP-42's, yet the 5 rivets that go thru these pieces PLUS the channel assembly are supposed to be CCP-44's. I got on a roll, and on both sides of the channel, had at least one place where I put a CCP-42 that should have been a -44. Drilled out and replaced.
Next, cut the aileron skin down to 38 29/32" in length. Used a cutoff wheel and the Andy snips. Then cut the angle that will match the outboard side of the wing taper. Weird markings on the plans, and since they pictured the right wing (I am working the left), it just seemed like the markings were wrong - seemed like the upper surface and lower were marked in completely opposite ways. Cut the pieces and it all came out just fine.
Also marked the cutouts for the counterbalance and aileron drive plate. Didn't cut, though...
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Jig to Level & Square the Counterbalance Assy
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Completed Assy
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Aileron Cut (rough cut)
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