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Zenith CruZer & Sonex Logs
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Date: 2-7-2009
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Number of Hours: 4.70
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Manual Reference: SNX-W05
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Brief Description: Prepare Left Flap
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Missed several days due to tax preparation and work issues. *sigh*
Started off today by re-drilling a metal yardstick to provide correct spacing for the hinge holes. I had previously drilled it 1/4" in from the edge, but forgot that this edge would then go against the hinge part, resulting in a 5/16" distance from the edge.
Previously, the only activities on the flap were the cutting of the angles and the notch to accomodate the actuator plate.
Today, I measured and drew the rib positioning lines, then the corresponding spacing marks for each rivet hole. Then pilot drilled the skin to #40. Only drilled the 4 upper holes for the wing mounting surface (left off the hinge line of rivets). Marked the centerline of the ribs, positioned them in the wing, and pilot drilled the ribs.
Made up a jig of two pieces of channel stock - an .032 piece and an .025 piece, and clamped it to the table on top of a 6' straight edge (to ensure a smooth surface). This will provide proper spacing for the hinge on the mounting surface. Used another hinge halve with the hinge pin in to provide some additional "straightness" to the hinge, since this is almost 6' long, and other builders have had problems getting the pin inserted on the airplane.
Pilot drilled the hinge holes. Went back and up-drilled to #30 all hinge holes, then did all the rib holes as well.
All that remains is the full deburr deal, then rivet. Man - it feels great to spend only 2-3 sessions and have a large assembly done after working for 5 months on the wings!
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.025 & .032 Channel Stock to make .057 Hinge Spacer
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Hinge Pilot drilled
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Me Updrilling to #30
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