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Zenith CruZer & Sonex Logs
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Date: 3-8-2009
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Number of Hours: 1.70
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Manual Reference: SNX-W03
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Brief Description: Right Aileron Counterweight Assy
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Lead weight was previously cut into left and right aileron sections, but the right one had not been drilled yet.
Positioned the lead between the counterweight arms, ensured they were square, clamped with visegrips, and then pilot drilled. The first time thru on the left aileron, I got too ambitious and tried to do more than the recommended 1/2 way thru from each side, causing the bit to jam. This time, I only drilled thru about 1/2 way, then flipped over the assy and continued from the other side. No drill bit jams in the lead this time.
End hole size is 3/16" for the AN3-14A hardware that secures the lead to the arms. You must step-drill up to that size. After the #40 pilot, I moved up to #30, then 5/32, then the 3/16. After the 3/16 pass, used the reamer a few times thru each hole to get to a point where then AN3 would pass thru the lead.
Next, left the lead bolted in position for alignment purposes, and positioned the aileron ribs to the counterweight arms. Clamped into position and pilot-drilled the ribs.
Next up: position the channel assy into place, up-drill all and rivet the counterweight assembly. Then position the ribs in the skin, drill, and rivet.
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