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Zenith CruZer & Sonex Logs
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Date: 8-16-2009
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Number of Hours: 3.50
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Manual Reference: SNX-F11
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Brief Description: Drill Splice Plates / Fit Tunnel Zee
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Felt productive today. Rough getting started though. Whine whine whine.
Pilot drilled the fwd / aft fuse longeron splice plates. 16 holes total, 4 on each corner. Picture below shows the right upper (remember, fuse is inverted in these shots). Had to use the 12" #40 drill bit, since the only pilot holes were in the splice plates themselves. The drilling had to go thru the longeron and thru the side skins / bottom skins as required.
Had to use C-clamps on the lower longeron splice plates to hold them tight against the longerons and each other. Will need to procure some wing-nut cleco's that are designed with more pulling strength to hold parts together. All 16 holes will be up-drilled to #12 (3/16") for AN525 hardware after all other trial fitments are done.
Moved on to the tunnel zee. You must first remove the aft wing mounting angle (it was only cleco'd into position during fuse side panel construction) in order to give room to drill the fwd tunnel zee as shown in picture 2 below. Several builders have commented on taking steps to ensure that the zee is not bowed in the middle during installation otherwise the wing spars will not fit. Marked the centerline of the zee, slid it into position, and the line was spot dead-on visible in the pre-drilled pilot holes in the lower skin. Pilot drilled the zee into position, clamped the sides, then used the 12" drill to fit the zee to the forward wing mount angle as shown in the second picture below.
Next, I positioned the aft tunnel zee between the aft wing mount angles (still not mounted to the fuse) (after marking the centerline of that piece as well...), and slit the assembly into position, shown in the 3rd picture below. The line is not visible at all; appears to be straight, but is just not visible in the prepositioned pilot holes. I used a Sharpie to mark the location of each hole from above (fuse inverted, remember?), and will dis-assemble tomorrow to re-draw the line. It's starting to look like a real cockpit!
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pilot drilled right upper splice plates
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Pilot drilled left side fwd tunnel zee
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Clamped in position aft tunnel zee
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