---------------------------------------------------------- Zenith-List Digest Archive --- Total Messages Posted Mon 03/24/03: 5 ---------------------------------------------------------- Today's Message Index: ---------------------- 1. 07:40 AM - Re: Rudder Nose Skin- 601XL (g t) 2. 11:26 AM - Holes in seat bottom for cables on 701 (owner-zenith-list-server@matronics.com) 3. 06:59 PM - Re: Rudder Nose Skin- 601XL (nhulin) 4. 07:49 PM - new address (Robert Wetzel) 5. 11:15 PM - Locating holes in the blind (Jim Frisby) ________________________________ Message 1 _____________________________________ Time: 07:40:27 AM PST US From: g t Subject: Re: Zenith-List: Rudder Nose Skin- 601XL --> Zenith-List message posted by: g t Larry, Sorry to hear about your nose skin problem. I did "exactly" the same thing at the rudder school. Two things that I did wrong included 1) Not having the nose skin high enough on the rudder (Although as you found out - this only accounts for several mm's of edge distance) and 2) the nose rib was installed with a 90 degree angle to the spar as the instructions called for. Just before drilling, I was told to push the nose rib up in order to get the skin tight. The got tight, but it also pulled out enough that I too only had 3mm of edge distance. The 90 degree angle is critical as pushing it up only a few degree is really pushing out the nose skin a lot based upon the geometry. Another possibility for your results could be a mislocated nose rib. If it is too high you will end up pushing the skin away from the spar. Also check you skin size to make sure it was not cut short originally, there should be excess material. A valuable lesson was learned by my mistake and that is "when" (Not if) I get permission to buy the rest of the kit, I will draw a minimum penetration line on skins that go in and get drilled with no ability to see how much overlap you have. As long as the line is not visible, you will automatically have sufficient edge clearance. Hope this helps you out. Good Luck, Tom TGrones@Charter.net Rudder School Done, Still persuading the better half. Zenith@portouw.com wrote:--> Zenith-List message posted by: Well, Ive just screwed up my rudder nose skin. I mounted it and drilled it yesterday and when I removed it, much to my horror discovered that the edge distance for the holes varied between 3mm at the top and 5mm at the bottom. Not going to work. Im trying to analyze what happened. It fits tight to the ribs. At first I thought that sliding the skin toward the top of the rudder would help, but I only gain about 2mm by doing that for a uniform 6mm edge distance with careful placement. Perplexed at this point. The part is clearly junk, but I need to figure out what happened before I go after a second attempt. Ill call Zenith on Monday. Maybe the skin is too small? Has anyone else run into this? Does anyone know the max distance along the front face of the spar from the bottom of the spar to the bottom edge of the nose skin. Larry Portouw Ft. Huachuca, AZ (FHU) --------------------------------- ________________________________ Message 2 _____________________________________ Time: 11:26:33 AM PST US From: owner-zenith-list-server@matronics.com Subject: Zenith-List: Holes in seat bottom for cables on 701 --> Zenith-List message posted by: Hello list members. I am about to prime the forward fuselage on my Z 701, and before I do that I will need to drill some holes in the seat bottom for the rudder cables and other hoses and wires, such as the airspeed and pitot tubes, fuel hoses and battery cable. (understand that the battery will need to be in the rear fuselage if using the Rotax 912 for a Zenith 701) My question is, how did you route these cables and hoses? Did you use the channel above the door for fuel and airspeed tubes? Is it possible? I do not want to drill too many holes in the seat bottom if there is no need for them. Your advise is appreciated. Best wishes, Johann G. Iceland. Stol 701 ------------------------------------------------- ________________________________ Message 3 _____________________________________ Time: 06:59:32 PM PST US From: "nhulin" Subject: Zenith-List: Re: Rudder Nose Skin- 601XL --> Zenith-List message posted by: "nhulin" > I'm doing a 701, and the problem is the same, mostly. That is, how to locate > reference points that are covered by skin. There is a simple way to get edge distances on hidden flanges such as the wing spar but you can probably adapt this idea for a lot of other situations. It is a variation of the rivet hole finder. Take two pieces of scrap 0.025 about 100mm long and 15mm wide (the actual dimensions don't matter). Put a 90 degree bend in the end of one about 5mm from the end. Line up the other piece along the back of the bent piece so that the end is level with the inside of the bend. When the pieces are together, drill and rivet the end opposite the bend. Two rivets is all that is needed. To help visualize the way the two pieces fit together imaging a 7 and a 1 next to each other but joined at the bottom. Mark down from the bend the correct edge distance and drill a #40 hole. This is your pilot hole. To use this device, slip the bent piece under the skin and hook the spar or hidden flange. The straight piece is on top of the skin and the end lines up with the edge of the spar or flange (handy for marking) and the #40 hole is the correct distance from the flange edge. Draw tick marks at the appropriate rivet interval and simply slide the tool along until you see a tick mark through the pilot hole - drill. Couldn't be simpler. I'll see if I can get a photo and diagram up on the photo share. Hope that this helps someone. I know that it make the work on the spar flange a whole lot simpler, faster, and less error prone. ...neil Neil Hulin 601XL (wings and stuff - still...) Cincinnati, Ohio ________________________________ Message 4 _____________________________________ Time: 07:49:47 PM PST US From: "Robert Wetzel" Subject: Zenith-List: new address , "Emil Giordano" , "Henry Schmidt" , "Jim Lartin-Drake" , "John Wetzel" , , "Michael Brook" , "Olenik Aviation" , "Paul and Ethel" , "Ron Steber" , , "STERNER,KERRY J." , "The Good Sam Club" , "Wasylik" , , "Wetzel, Robert J" , , , , , , , , , --> Zenith-List message posted by: "Robert Wetzel" Please use lufthund@netzero.net for any Emails Thanks Bob Wetzel - This message was sent from: http://www.regiononline.com ! Stop by and see what's going on in YOUR region NOW! ________________________________ Message 5 _____________________________________ Time: 11:15:01 PM PST US From: "Jim Frisby" Subject: Zenith-List: Locating holes in the blind --> Zenith-List message posted by: "Jim Frisby" I used some small (3/8" diameter, 3/16" thick) round magnets. I taped them to the flange to be drilled into, such that their centers were along the rivet line. You can pre-test the magnetic lines of force so you know how it will look, by centering the magnet behind a mark on a piece of aluminum and sprinkling filings over it. Observe the shape of the pattern in relation to the mark. Then, when the skin was clamped in place, I sprinkle some iron filings over the magnets. From the pattern of the filings, it is easy to see where the center of the magnet is. I draw lines between the magnets on the skin and drill for the rivets along the line, works great. Jim Frisby Palmer, AK