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Zenith CruZer & Sonex Logs
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Date: 12-6-2009
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Number of Hours: 3.40
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Manual Reference: SNX-C01
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Brief Description: Flap Tube Fitting / Brake Lever Assy
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I decided to get started on the "under tank" stuff. Did not have to remove glareshield today, so I worked on fitting the flap tube and brake lever, since they were not tucked under the glareshield much.
First step was to chamfer the inner flange of the phenolic blocks on the pilot's side. In pic one below, the chamfer is on the inner side of the blocks. This is because the weld fillet for the flap handle prevents the blocks from fitting on the tube. Chamfered quite a bit with a carbide cutter tip in my Dremel tool. Dust everywhere. Used a hazmat face mask to keep from breathing the dust and odor.
Had to ream out the blocks and the attach angles to allow smooth yet firm insertion of the AN3 bolts.
Cut the flap handle to length from bar stock. Bent the handle 25 degrees as per plans. Drilled 3/16" holes for the pivot point and for the cable attach location. Next, I had to locate and drill the lever stop plate, shown on the bottom of the assy in picture 2. This keeps the lever from going past 75 degrees, which would loosen the brakes too much (pull to apply).
The assembly bracket fits on the bottom of the flap tube attach angle. This was a bear to fit. The brake attach angle was pre-drilled with holes, but failed to take into account the fillet of the flap attach angle. Also, since the fuse sides angle in toward the front, this angle interfered with some of the rivets from the flap hole reinforcement. Many attempts at fitting, filing, fitting, filing, etc.
Finally got it to fit. Put the nuts on the bolts, then discovered that I forgot to a) grease the flap tube where it fits in the phenolic blocks and b) add washers under the AN3 bolt heads. Took both sides apart, lubed, and added washers.
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Initial Fitting of Flap Tube (Brake Lever Support Absent)
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Brake Lever Assy
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Flap Tube / Brake Lever
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