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Eddie's Zodiac XL Project
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Date: 3-8-2006
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Number of Hours: 4.00
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Manual Reference:
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Brief Description: Right wing nose skin
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I asked Dusan come over to help me lift the nose skin into place, given its length and the fact that it was folded, I was not willing to take the risk of doing this on my own.
Befroe starting, the rear skin was marked with the position of the rear ribs and the nose ribs where attached and the centre lines marked. so that they could be lined up with the nose skin.
The nose skin was measured and the centre of the bend marked at each end. With this done the nose skin was lifted into place. I decided that I would actually back drill the leading edge of the rear bottom skin and slide the nose skin under the rear skin for back drilling, rather than overlap on the top and use tape to hold it in place.
The centre line o the skin and the ribs did not line up as described in the plans to allow for a 10mm edge distance for the rivets as well as being able to back drill into the centre of the main spar L angle, so I adjusted the nose skin to give these tollerances and back drilled through the leading edge into the nose skin. The center lines for the rear ribs where then transferred onto the nose skin and the rivet pitch laid out. With this done the nose skins where back drilled with the nose ribs being moved out of the way, once the back drilling was done, the nose ribs where repositioned to show the centre lines through the #40 pilot holes and the nose skin was drilled one row at a time from the main spar towards the front of the nose skin.
The end result was very good and it looks like the nose skin will wrap around the ribs without any graps. The only mistake I made while lining up the nose skin was to push to hard on the skin while positioning it and I ended up putting a dent into the leading edge of the skin at NR# 7, I managed to get most of it out and it does not look too bad, I just hope it not obvious once painted.
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O/B Shot of nose skin clecoed in place
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I/B shot of nose skin clecoed in place
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Shot of the dent in the skin, its just visible in this shot
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