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Zenith CruZer & Sonex Logs
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Date: 2-24-2009
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Number of Hours: 1.00
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Manual Reference: SNX-W03
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Brief Description: Left Aileron Tip Rib
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Lots of consternation trying to test-fit the left aileron tip rib. Initial placement just would not line up - see first pic below. If it lined up on the vertical hinge surface, the tip of the rib was about 1/2" offset from the skin. If I got the rib to fit into the skin, there was about a 1/8" gap at the upper right corner in the pics below.
Finally just brute-forced it. Another builder's website suggested lining up the bottom side (upper in the pics) of the skin, and cleco'ing that first, then the upper side. That actually worked OK. Had to brace the aileron to drill the upper skin surface, as the tip rib is actually set inside the skin just a bit, in order to have the angle of the rib line up flush with the edge of the skin.
After all that, the hinge surface of the skin was pretty durn close. If you look real close, you can see the upper right corner has a slight pucker to it; I'll just have to fill that in with some micro-balloons prior to paint.
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Initial Fit - Seemed like angles wrong
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Well, not perfect, but not bad
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