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Zenith CruZer & Sonex Logs
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Date: 12-8-2011
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Number of Hours: 4.50
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Manual Reference: misc
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Brief Description: Updrilled Wingtips / Wheelpant Reinforced / Wing D
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Long day, but productive. Lots got done toward completion.
Started out by reinstalling both wingtips onto the wings. When I first did this, I only pilot-drilled the holes, so this time I cleco'd every other hole (the wing would buckle otherwise) and up-drilled to #30. Re-cleco'd the just-drilled holes and removed the remaining #40 cleco's, then updrilled those holes. Removed the tips and deburred the holes.
Spent some time inspecting the new yellow-painted tips. Did some sanding with #400 paper, but it's only been 24 hrs since I painted, and it was still too soft. Will touch-up sanding in a day or two.
Next, after talking with Sonex Tech Support, they urged me to replace the S48 screws in the side of the fuselage to hold the windshield in place. Lowes had the correct length screws, but of course the countersink angle is different from the MS24693 screws. I didn't have any more of the correct length. My son was in town, and I really needed him to help me get the forward screws in due to the distance to the front of the glareshield. I removed some S50 screws I had in other locations, installed some S48s (marked so I don't forget), then replaced some of the screws (the hard to reach ones) on the fuselage side/windshield attach.
Next, several builders reported that their wheelpants cracked where the mounting screw goes into the axle. Installed two layers of glass matte over washers to help provide reinforcement (both pants).
Lastly, I riveted the wing doublers on both wings. Only had to drill-out and replace one rivet. Had some rivet issues with the new rivets - the mandrell pulled right thru in a few cases and became jammed in the nose of the riveter. Had to remove the nose and literally drive-out the stuck mandrel. Otherwise OK.
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Glassed-In Reinforcement Washer
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Doublers Installed Both Wings
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