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SCOTT'S WEB SITE
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Date: 3-4-2004
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Number of Hours: 21.20
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Manual Reference:
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Brief Description: The rudder kit
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Assembly by Scott Thatcher. Received the rudder starter kit for the Zodiac 601 XL on March 4, 2004 along with tools required to assemble the rudder. These tools consisted of Hand Riveter, Clecos, Cleco Pliers, Rivets, Snips (L & R), several drill bits (#20, #30 and #40) and metric tape measure. Review rudder assembly manual and photograph box (excellent shipping container). Mark inside of main spar (rudder) for rivet line. Drill using #30 (for 1/8” clecos), Join doublers to main spar and trim ends using snips. Mark rivets 40mm from any ribs and visually adjust if short at ribs (occurred only once). Mark centerlines on all ribs and back drill for placement. Use 1/8”clecos every other hole.Cleco ribs #2, 3 and #4. Cleco Nose rib and top rib in place. Remove all clecos. Debur all drill holes. Zinc chromate applied to all rivet lines, front and back. Bill recommended use of green zinc chromate. (why?) Layout rivet pattern on skin. Drill and cleco all rivets. Remove rib #2 and reverse. Flange in wrong direction.Remove clecos and debur. Add zinc chromate to skin (inside Cleco skin up to spar. Measure rivet line on nose piece. Place under rear skin and tape. Cleco nose skin in place and mark the cut of top skin (continue straight line of back skin). Cut nose skin, debur rivets add zinc chromate to rivet line and complete rivet entire rudder. 0021:10
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