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Zenith CruZer & Sonex Logs
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Date:  6-9-2010
Number of Hours:  1.20
Manual Reference:  SNX-D01
Brief Description:  Drilling Lexan / Dimpling Holes / Marking Fwd Edge

Felt like I got stuff done tonight; was at EAA Chapter meeting last night.

Using a compass, I set it for 1", which is the set-back distance for the windscreen from the fwd edge of the firewall upper bow. The pencil marked the protective film just fine, but I added a line of tape to provide better contrast.

Next, I drilled thru the existing fuselage holes thru the lexan in preparation for countersinking.

Removed the lexan and dimpled the fuselage sides with the rivet squeezer. It was a tight fit at the fwd-most hole on each fuselage side, so I dimpled-thru the fuselage side and the firewall bow, then went back and squeezed the firewall bow back to a flat condition with my flanging pliers.
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Used a compass to set 1

Used a compass to set 1" distance from edge of firewall bow

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Dimpling fuselage sides

Dimpling fuselage sides

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Closeup of fwd-most hole

Closeup of fwd-most hole

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