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Zenith CruZer & Sonex Logs
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Date: 5-1-2009
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Number of Hours: 3.70
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Manual Reference: SNX-F21
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Brief Description: Aft Fuse Cross Ties
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Got really frustrated earlier in the week; just couldn't seem to get stuff squared up. Finally took Jeremy Monnett's suggestion, and took it off the bench and put it on sawhorses. This was quite a revelation. Things just seemed to go better, overall. Things squared up just fine.
Cleco'd all open holes in the longerons (vertical skin side) at the suggestion of Jeremy. Finished drilling all lower skin holes; cleco'd more than every other hole (was running low on 3/32 cleco's).
Crawled underneath to pilot drill (2 holes) in each end of the lower crossties. Re-verified squareness once I crawled back out from underneath, then went back under and finished drilling all other lower crosstie pilot holes (remember; fuse was still upside down).
Turned over the fuse so up was now up. Approximated placement of upper crossties and lightly clamped. Could still move.
Fitted the crosstie box subassembly. Had to trim a little less than 3/32 off each end as some other builders have had to do. This was a measure, trim, retry, trim some more, then clean it up effort. Once the fit was correct to retain the 40" spacing at the fuse skin bend lines, I removed the cleco's holding the upper splice plate so the crosstie box would fit flush with the splice plates. Drilled pilot holes thru the vertical channels. Then drilled thru the splice plates and into the crosstie box.
Still have to install the clips on the backside of the crosstie box, then up-drill to take 2 AN-3 bolts thru the splice plates. Other bolts are installed on the vertical skin side of the splice plates as part of fitting the turtledeck.
Measured upper/lower widths at each of the upper / lower x ties. Reconfirmed still square (amazingly, they were!). Positioned and clamped upper x ties to final measurement. Still have to drill.
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Upside down; Ready for lower crossties
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Co-Pilot Checking Squareness
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Right Side Up, CrossTie Box Installed; Upper Crossties Placed
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