---------------------------------------------------------- Zenith-List Digest Archive --- Total Messages Posted Fri 07/28/06: 54 ---------------------------------------------------------- Today's Message Index: ---------------------- 1. 12:07 AM - (kevinbonds) 2. 04:02 AM - Re: (Paul Mulwitz) 3. 04:31 AM - Re: Firewall rivets (dj45) 4. 04:33 AM - Re: 601XL Gear (Robin Bellach) 5. 04:35 AM - Re: (landing gear) (Daniel Dempsey) 6. 05:20 AM - Re: Left-Right "Mags" (Geoff Heap) 7. 05:20 AM - Re: Left-Right "Mags" (Mike & Kerin Gleason) 8. 05:28 AM - Re: Left-Right "Mags" (Zed Smith) 9. 05:53 AM - Hat Stiffener Press + Pic of the day (Debo Cox) 10. 05:56 AM - Re: 912 tach problem (Zed Smith) 11. 06:01 AM - Rivet gun (Bob Gibfried) 12. 06:11 AM - Re: 912 tach problem (David X) 13. 06:37 AM - Re: Rotax 912 Tachometer Problems (Paul Tipton) 14. 06:42 AM - Re: Rotax 912 Tachometer Problems (Noel Loveys) 15. 07:37 AM - Re: Firewall rivets (Noel Loveys) 16. 07:49 AM - Stabilizer end rib cutout position for 601XL (lwinger) 17. 08:08 AM - Re: Hat Stiffener Press + Pic of the day (TxDave) 18. 08:25 AM - Re: Stabilizer end rib cutout position for 601XL (Tom Henderson) 19. 08:26 AM - Re: strut coating (N5SL) 20. 08:51 AM - Re: Left-Right "Mags" (NYTerminat@aol.com) 21. 10:15 AM - Re: Looking for Zenith amphib float kit manual (Russ GREENWAY) 22. 11:56 AM - Re: Composite gear (kevinbonds) 23. 11:56 AM - Coomposite Gear (kevinbonds) 24. 11:56 AM - Re: (landing gear) (kevinbonds) 25. 11:58 AM - Re: Hat Stiffener Press + Pic of the day (kevinbonds) 26. 12:21 PM - Re: Hat Stiffener Press + Pic of the day (kevinbonds) 27. 12:49 PM - Re: Coomposite Gear (Randy Bryant) 28. 12:49 PM - Re: Re: Firewall rivets (Gary Gower) 29. 01:05 PM - Re: Coomposite Gear (NYTerminat@aol.com) 30. 01:15 PM - Re: Re: Firewall rivets (Dave Ruddiman) 31. 01:26 PM - Ch 620 (Tom Henderson) 32. 02:45 PM - Re: Hat Stiffener Press + Pic of the day (Debo Cox) 33. 03:01 PM - Re: Ch 620 (Crvsecretary@aol.com) 34. 04:10 PM - Re: Firewall rivets (dj45) 35. 04:13 PM - Re: strut coating (LarryMcFarland) 36. 04:35 PM - Re: Firewall rivets (VideoFlyer@aol.com) 37. 04:57 PM - Re: Hat Stiffener Press + Pic of the day (Monty Graves) 38. 05:06 PM - Re: Hat Stiffener Press + Pic of the day (ihab.awad@gmail.com) 39. 05:54 PM - Re: strut coating (ron dewees) 40. 07:18 PM - Re: strut coating (ron dewees) 41. 07:28 PM - Re: Ch 620 (Ashcraft, Keith -AES) 42. 07:38 PM - Plating Zodiac landing gear (George Swinford) 43. 07:44 PM - Re: Hat Stiffener Press + Pic of the day (Ron Lendon) 44. 07:56 PM - Re: Coomposite Gear (Ron Lendon) 45. 08:49 PM - Re: Coomposite Gear (kevinbonds) 46. 08:53 PM - Re: Rotax 912 Tachometer Problems (David X) 47. 09:06 PM - Re: Coomposite Gear (David X) 48. 09:40 PM - Re: Night VFR with a Rotax (David X) 49. 10:03 PM - Re: Coomposite Gear (TxDave) 50. 10:12 PM - Re: Weight & Balance (David X) 51. 10:33 PM - Olfa Knife Cutting Nose Ribs (Ron Lendon) 52. 10:45 PM - Re: Coomposite Gear (David X) 53. 11:41 PM - Re: Firewall rivets (Gary Gower) 54. 11:53 PM - Re: Rotax 912 Tach Problems now News people... (Gary Gower) ________________________________ Message 1 _____________________________________ Time: 12:07:23 AM PST US From: "kevinbonds" Subject: Zenith-List: I can't make up my mind about what gear to use on my XL. I began fabrication the necessary parts for the Composite gear from AS tonight, but began to worry about the longevity of a Composite structure for landing gear. I don't want to have to worry about the gear beginning to crack in the future. I don't know if I'll be able to find a replacement 10-15 years from now. The pluses are 1) it would save a ton of weight. 2) it would save a ton of weight. The minuses are 1) increase in complexity 2) more time 3) slightly more expensive 4) wont be easily converted back to standard gear if needed 5) How long will it last? I would benefit from some discussion on the topic. Does anyone have anything to add? Kevin Bonds Nashville TN 601XL Corvair powered; Plans building. Empennage done; working on wings and engine. http://home.comcast.net/~kevinbonds do not archive DO NOT ARCHIVE ________________________________ Message 2 _____________________________________ Time: 04:02:13 AM PST US From: Paul Mulwitz Subject: Re: Zenith-List: Hi Kevin, There are composites, and then there are different composites. I don't have any idea which ones you are thinking of using on your landing gear, but the difference can be night and day. I suspect the metal landing gear would last forever under most circumstances. The composites, however, might start sagging and warping the first day they get hot because of being parked on asphalt on a hot day. I don't know the variables, but I am not brave enough to try to engineer something as important as landing gear. I would stick with the original designer's choices. Paul XL fuselage do not archive >I can't make up my mind about what gear to use on my XL. I began >fabrication the necessary parts for the Composite gear from AS >tonight, but began to worry about the longevity of a Composite >structure for landing gear. I don't want to have to worry about the >gear beginning to crack in the future. I don't know if I'll be able >to find a replacement 10-15 years from now. The pluses are 1) it >would save a ton of weight. 2) it would save a ton of weight. The >minuses are 1) increase in complexity 2) more time 3) slightly more >expensive 4) wont be easily converted back to standard gear if >needed 5) How long will it last? I would benefit from some >discussion on the topic. Does anyone have anything to add? > > - ________________________________ Message 3 _____________________________________ Time: 04:31:17 AM PST US From: "dj45" Subject: Zenith-List: Re: Firewall rivets --> Zenith-List message posted by: "dj45" It puts out 180 hp. They have a rather informative web site. I have spent a lot of time on this choice. I belive it is the way to go for what we want to use the plane for Read this topic online here: http://forums.matronics.com/viewtopic.php?p=50258#50258 ________________________________ Message 4 _____________________________________ Time: 04:33:44 AM PST US From: "Robin Bellach" <601zv@ritternet.com> Subject: Zenith-List: Re: 601XL Gear I think the Grove gear is a good compromise as it offers very significant weight savings without the dissadvantages of composite. By the way, does anyone have a list, preferable one with prices, for the ZAC Gear kit? I would help me decide which gear parts to get from ZAC, and which from Grove and others. Robin of Jasper, AR 601XL / 2900 Wynne-Vair N601ZV ----- Original Message ----- From: kevinbonds To: zenith-list@matronics.com Sent: Friday, July 28, 2006 2:04 AM Subject: Zenith-List: I can't make up my mind about what gear to use on my XL. I began fabrication the necessary parts for the Composite gear from AS tonight, but began to worry about the longevity of a Composite structure for landing gear. I don't want to have to worry about the gear beginning to crack in the future. I don't know if I'll be able to find a replacement 10-15 years from now. The pluses are 1) it would save a ton of weight. 2) it would save a ton of weight. The minuses are 1) increase in complexity 2) more time 3) slightly more expensive 4) wont be easily converted back to standard gear if needed 5) How long will it last? I would benefit from some discussion on the topic. Does anyone have anything to add? Kevin Bonds Nashville TN 601XL Corvair powered; Plans building. Empennage done; working on wings and engine. http://home.comcast.net/~kevinbonds do not archive DO NOT ARCHIVE ________________________________ Message 5 _____________________________________ Time: 04:35:57 AM PST US From: Daniel Dempsey Subject: Re: Zenith-List: (landing gear) Kevin, I had decided to go for ACS composite gear. One more drawback. It has been 9 weeks since I ordered the parts. Still on back order. Luckily I have plenty of parts left to make so I haven't been held up... yet. Dan Dempsey (XL/Corvair) ----- Original Message ----- From: kevinbonds To: zenith-list@matronics.com Sent: Friday, July 28, 2006 3:04 AM Subject: Zenith-List: I can't make up my mind about what gear to use on my XL. I began fabrication the necessary parts for the Composite gear from AS tonight, but began to worry about the longevity of a Composite structure for landing gear. I don't want to have to worry about the gear beginning to crack in the future. I don't know if I'll be able to find a replacement 10-15 years from now. The pluses are 1) it would save a ton of weight. 2) it would save a ton of weight. The minuses are 1) increase in complexity 2) more time 3) slightly more expensive 4) wont be easily converted back to standard gear if needed 5) How long will it last? I would benefit from some discussion on the topic. Does anyone have anything to add? Kevin Bonds Nashville TN 601XL Corvair powered; Plans building. Empennage done; working on wings and engine. http://home.comcast.net/~kevinbonds do not archive DO NOT ARCHIVE ________________________________ Message 6 _____________________________________ Time: 05:20:56 AM PST US From: "Geoff Heap" Subject: Zenith-List: Re: Left-Right "Mags" --> Zenith-List message posted by: "Geoff Heap" Tommy. Try the rotax list. I was recently reading posts on this subject post by "jon(at)joncroke.com" part of what he wrote "Note that the Rotax purists will probably scold you (using an Austrian accent!) for saying left or right.? We have a top (A) and a bottom (B) ignition module... regardless of what the key switch says.? " post subject is "912 rough running"...............Geoff Read this topic online here: http://forums.matronics.com/viewtopic.php?p=50265#50265 ________________________________ Message 7 _____________________________________ Time: 05:20:56 AM PST US From: "Mike & Kerin Gleason" Subject: Re: Zenith-List: Left-Right "Mags" --> Zenith-List message posted by: "Mike & Kerin Gleason" Tommy: Its not critical, Mine are wired A as right and B as left. Mike G 701 awaiting inspection do not archive > > I don't know if it is critical, but I would like to know. > > Thanks, > > Tommy Walker in Alabama > Do Not Archive > > > > > > > > > > > > > > > > ________________________________ Message 8 _____________________________________ Time: 05:28:51 AM PST US From: Zed Smith Subject: Re: Zenith-List: Left-Right "Mags" --> Zenith-List message posted by: Zed Smith Tommy, You are right ....."A" & "B" probably should be 1 & 2 or Left & Right. I ran into that same thing and decided that it really only mattered to the guy doing the mag check....if you need to troubleshoot later it just makes it easier if you know which Module is connected the Left/Right toggle switch or position on the key switch. I used white heat shrink over the two wires, on each end, and a fine-point Sharpie solved the labeling. Regards, Zed do not archive ________________________________ Message 9 _____________________________________ Time: 05:53:19 AM PST US From: Debo Cox Subject: Zenith-List: Hat Stiffener Press + Pic of the day After a few failed attempts at making hat stiffeners for the main spar, I decided to try making a press die for them in much the same way I made my flanging dies. Here's what I came up with. I used the same timbertech composite material as I used for the flanging dies, and was able to fabricate the whole set using a table saw and some 5-minute epoxy from ACE hardware. I rounded all of the corners to the proper radius, and epoxied the male 45-degree press flange to the top die. To use them, I put a piece of .025 between the dies and put them under pressure with the shop press until the bend is formed, then trim the flanges to the proper size. Out comes perfectly shaped, high-quality, repeatable hat stiffeners lookin' like the factory made 'em. Debo Cox Nags Head, NC XL/Corvair Moving slow, but still moving (which is good) --------------------------------- ________________________________ Message 10 ____________________________________ Time: 05:56:11 AM PST US From: Zed Smith Subject: Zenith-List: RE: 912 tach problem --> Zenith-List message posted by: Zed Smith One problem that has surfaced concerning the 912 and electronic tachs is nearly what you described as "erratic". The tach pickup coil on the 912 puts out an AC waveform that is not a pure sinewave....it has "ringing" riding on the AC which, viewed on a 'scope, looks like a lot of spikes or bumps. If a "load" is put on the tach pickup leads this ringing disappears. These newer tachs are "counters" which count the number of oscillations and display it as RPM. Having a "high input impedance" results in the tach counting each little spike as a revolution. Some spikes are counted, some are not. Erratic display. There may even be a maximum signal input voltage spec, but I'm not aware of it. Put a 150 Ohm resistor across the tach leads to swamp the pickup output. This will reduce the ringing/spikes and allow the tach to read/count only the revs. WesTach has included this in the installation instructions in recent shipments, unfortunately mine was purchased prior to that so I spent hours messing with it. Other brands probably suffer the same symptoms. Hope this is helpful, Zed/701/R912/90+%/do not archive ________________________________ Message 11 ____________________________________ Time: 06:01:28 AM PST US From: "Bob Gibfried" Subject: Zenith-List: Rivet gun Harbor Freight just reduced their rivet gun to $29.99 with an on line cou pon . At that price, having a spare is worthwhile. Bob, Wichita ________________________________ Message 12 ____________________________________ Time: 06:11:06 AM PST US From: "David X" Subject: Zenith-List: Re: 912 tach problem --> Zenith-List message posted by: "David X" Thank you, I'll give it a try. -------- Zodiac 601 XL - CZAW Built - Rotax 912S DO NOT ARCHIVE Read this topic online here: http://forums.matronics.com/viewtopic.php?p=50286#50286 ________________________________ Message 13 ____________________________________ Time: 06:37:56 AM PST US From: "Paul Tipton" Subject: Re: Zenith-List: Rotax 912 Tachometer Problems Am I missing something? You guys have some good info on problems, so why would you put "Do not archive" on your messages? Being an old fart, I am not going to be able to remember all this info on the top of my head. Doesn't the DNA stop anyone from finding it later? Or maybe I just don't understand all this new fangled stuff. ________________________________ Message 14 ____________________________________ Time: 06:42:56 AM PST US From: "Noel Loveys" Subject: RE: Zenith-List: Rotax 912 Tachometer Problems It sure sounds like the effects of a wire chafing on a ground somewhere. Noel -----Original Message----- [mailto:owner-zenith-list-server@matronics.com] On Behalf Of NYTerminat@aol.com Sent: Thursday, July 27, 2006 7:52 PM David, The pickup for the tach signal puts out an AC voltage. You can look in your Rotax manual to see what it is supposed to be. I would hook up an AC Voltmeter, connect one lead from your pickup coil output on your engine and the other to ground. If you are getting the specified voltage, you have a wire problem from there to your tach. Bob Spudis N701ZX CH701/912S do not archive In a message dated 7/27/2006 5:44:20 P.M. Eastern Daylight Time, dxj@comcast.net writes: An Aviasport tach that was working, but then started to act irratic and finally reads zero. I replaced the tach with a new one with no success. ________________________________ Message 15 ____________________________________ Time: 07:37:06 AM PST US From: "Noel Loveys" Subject: RE: Zenith-List: Firewall rivets --> Zenith-List message posted by: "Noel Loveys" If your fire wall is stainless steel then any rivets, nuts or washers attached to it should also be stainless to reduce the occurrence of dissimilar metal corrosion. I agree with Paul.... Get the stainless rivets. Noel > > I would suggest using only stainless rivets on the firewall of any > airplane. Aluminum rivets will melt quickly in an engine compartment > fire while the stainless rivets will withstand any temperature you > are likely to get. The stainless rivets are also quite a bit > stronger than similar sized aluminum rivets since they are steel. > > I guess a good rule of thumb is if the firewall is steel then you > should use steel hardware and parts on it. > > Good luck, > > Paul > XL fuselage ________________________________ Message 16 ____________________________________ Time: 07:49:03 AM PST US From: "lwinger" Subject: Zenith-List: Stabilizer end rib cutout position for 601XL --> Zenith-List message posted by: "lwinger" I'm fabricating 6T1-1 and have a question about the 18mm cutout at the back of the rib. While the plans say "2 req'd" (not "1L+1R"), it appears that I don't make two identical ribs. Rather, I presume that I should make one rib with the cutout as shown, and the other rib with it on the opposite side. Is that correct? -------- Larry Winger Tustin, CA 601XL #6493 from scratch Building stabilizer & rudder parts Read this topic online here: http://forums.matronics.com/viewtopic.php?p=50307#50307 ________________________________ Message 17 ____________________________________ Time: 08:08:45 AM PST US From: "TxDave" Subject: Zenith-List: Re: Hat Stiffener Press + Pic of the day --> Zenith-List message posted by: "TxDave" Debo, I've said it before, you're a genius. What a creative use of plastic lumber. do not archive Dave Temple, TX 601XL Read this topic online here: http://forums.matronics.com/viewtopic.php?p=50315#50315 ________________________________ Message 18 ____________________________________ Time: 08:25:32 AM PST US From: Tom Henderson Subject: Re: Zenith-List: Stabilizer end rib cutout position for 601XL --> Zenith-List message posted by: Tom Henderson You're right Larry. You're going to cut two identical ribs. Then you're going to form them in OPPOSITE directions. The end result is that you'll have one left and one right rib. If you're like many who don't like so see the mill writing on the outside of their parts, layout two ribs opposite of each other. Sounds like your project is coming along. Post some pics if you get a chance. Tom Henderson 601XL Fusealge lwinger wrote: >--> Zenith-List message posted by: "lwinger" > >I'm fabricating 6T1-1 and have a question about the 18mm cutout at the back of the rib. While the plans say "2 req'd" (not "1L+1R"), it appears that I don't make two identical ribs. Rather, I presume that I should make one rib with the cutout as shown, and the other rib with it on the opposite side. Is that correct? > >-------- >Larry Winger >Tustin, CA >601XL #6493 from scratch >Building stabilizer & rudder parts > > >Read this topic online here: > >http://forums.matronics.com/viewtopic.php?p=50307#50307 > > > > > > > > > ________________________________ Message 19 ____________________________________ Time: 08:26:53 AM PST US From: N5SL Subject: Re: Zenith-List: strut coating --> Zenith-List message posted by: N5SL I had my rudder pedals, steps and gear leg chromed last February and I really like the results. Before: http://www.cooknwithgas.com/2_02_05_PlatingParts.jpg After: http://www.cooknwithgas.com/2_19_05_Nosewheel.jpg http://www.cooknwithgas.com/2_19_05_Pedals.jpg I did make the gear plate slightly thicker. It has held up well for over a year now with hundreds of trips in and out of the garage (that was a joke). I got the idea from seeing Jeff Small's airplane a few years ago - Jeff has the nicest 601 I've ever seen in person. I paid just under $100 for all of the parts in that box. Here's a tip - if you want it to be really shiny and smooth, polish up the metal before bringing it to the chrome place. They charge more for polishing. I told them not to polish mine and I still like the way it looks. Scott Laughlin Omaha, Nebraska 601XL - Canopy complete! --- Jeff Small wrote: > > Mine has held nicely on three gear legs (HDS) for > four years. > > CAVU jeff __________________________________________________ ________________________________ Message 20 ____________________________________ Time: 08:51:22 AM PST US From: NYTerminat@aol.com Subject: Re: Zenith-List: Left-Right "Mags" Tommy, Rotax uses Ignition A and B. The A serves the top plugs of cyl 1 and 2 and the bottom plugs of cyl 3 and 4. The B ignition serves top plugs for cyl 3 and 4 and bottom plugs for cyl 1 and 2. It doesn't matter which you consider left and right as long as you know which is A and B for troubleshooting. Bob Spudis In a message dated 7/27/2006 7:45:55 P.M. Eastern Daylight Time, twalker@cableone.net writes: --> Zenith-List message posted by: "Tommy Walker" Rotaxers, I'm wiring up my kill switches on the 912. Which ignition module is Left and which is right? In the drawings there is a reference to A and B modules. I am thinking that A is left and B is right, but I have thought before and been proven wrong. I don't know if it is critical, but I would like to know. Thanks, Tommy Walker in Alabama Do Not Archive ________________________________ Message 21 ____________________________________ Time: 10:15:03 AM PST US From: "Russ GREENWAY" Subject: Zenith-List: Re: Looking for Zenith amphib float kit manual Please try to re post on Sea Plane list. thanks ----- Original Message ----- From: Russ GREENWAY To: zenith-list@matronics.com Sent: Monday, July 24, 2006 12:34 PM Subject: Looking for Zenith amphib float kit manual Thanks to you guys, I found a used Zenair amphib float kit but missing a couple of parts we think. Does anyone have a manual listing or diagram of parts/pieces for the Zenair kit. I would like to know which pieces may be missing and are still available before I purchase the kit and possibly be stuck with a kit I may not be able to use. thanks, Russ Greenway kylepilot@msn.com ________________________________ Message 22 ____________________________________ Time: 11:56:25 AM PST US From: "kevinbonds" Subject: RE: Zenith-List:Composite gear Aircraft Spruce offers composite landing gear for the XL. Sorry I wasn't clear. Kevin Bonds Nashville TN 601XL Corvair powered; Plans building. Empennage done; working on wings and engine. http://home.comcast.net/~kevinbonds do not archive DO NOT ARCHIVE _____ [mailto:owner-zenith-list-server@matronics.com] On Behalf Of Paul Mulwitz Sent: Friday, July 28, 2006 5:54 AM Hi Kevin, There are composites, and then there are different composites. I don't have any idea which ones you are thinking of using on your landing gear, but the difference can be night and day. I suspect the metal landing gear would last forever under most circumstances. The composites, however, might start sagging and warping the first day they get hot because of being parked on asphalt on a hot day. I don't know the variables, but I am not brave enough to try to engineer something as important as landing gear. I would stick with the original designer's choices. Paul XL fuselage do not archive I can=12t make up my mind about what gear to use on my XL. I began fabrication the necessary parts for the Composite gear from AS tonight, but began to worry about the longevity of a Composite structure for landing gear. I don=12t want to have to worry about the gear beginning to crack in the future. I don=12t know if I=12ll be able to find a replacement 10-15 years from now. The pluses are 1) it would save a ton of weight. 2) it would save a ton of weight. The minuses are 1) increase in complexity 2) more time 3) slightly more expensive 4) wont be easily converted back to standard gear if needed 5) How long will it last? I would benefit from some discussion on the topic. Does anyone have anything to add? - ________________________________ Message 23 ____________________________________ Time: 11:56:25 AM PST US From: "kevinbonds" Subject: Zenith-List: Coomposite Gear I can't make up my mind about what gear to use on my XL. I began fabrication the necessary parts for the Composite gear from AS tonight, but began to worry about the longevity of a Composite structure for landing gear. I don't want to have to worry about the gear beginning to crack in the future. I don't know if I'll be able to find a replacement 10-15 years from now. The pluses are 1) it would save a ton of weight. 2) it would save a ton of weight. The minuses are 1) increase in complexity 2) more time 3) slightly more expensive 4) wont be easily converted back to standard gear if needed 5) How long will it last? I would benefit from some discussion on the topic. Does anyone have anything to add? Kevin Bonds Nashville TN 601XL Corvair powered; Plans building. Empennage done; working on wings and engine. http://home.comcast.net/~kevinbonds do not archive DO NOT ARCHIVE ________________________________ Message 24 ____________________________________ Time: 11:56:25 AM PST US From: "kevinbonds" Subject: RE: Zenith-List: (landing gear) Thanks. I'll add that to the negative column. Kevin Bonds Nashville TN 601XL Corvair powered; Plans building. Empennage done; working on wings and engine. http://home.comcast.net/~kevinbonds do not archive DO NOT ARCHIVE _____ [mailto:owner-zenith-list-server@matronics.com] On Behalf Of Daniel Dempsey Sent: Friday, July 28, 2006 6:35 AM Kevin, I had decided to go for ACS composite gear. One more drawback. It has been 9 weeks since I ordered the parts. Still on back order. Luckily I have plenty of parts left to make so I haven't been held up... yet. Dan Dempsey (XL/Corvair) ________________________________ Message 25 ____________________________________ Time: 11:58:01 AM PST US From: "kevinbonds" Subject: RE: Zenith-List: Hat Stiffener Press + Pic of the day Messages like this one are why I stay on this list. This one is a gem. Bravo. I would never have thought of that. Kevin Bonds Nashville TN 601XL Corvair powered; Plans building. Empennage done; working on wings and engine. http://home.comcast.net/~kevinbonds do not archive DO NOT ARCHIVE _____ [mailto:owner-zenith-list-server@matronics.com] On Behalf Of Debo Cox Sent: Friday, July 28, 2006 7:52 AM After a few failed attempts at making hat stiffeners for the main spar, I decided to try making a press die for them in much the same way I made my flanging dies. Here's what I came up with. I used the same timbertech composite material as I used for the flanging dies, and was able to fabricate the whole set using a Debo Cox Nags Head, NC XL/Corvair Moving slow, but still moving (which is good) ________________________________ Message 26 ____________________________________ Time: 12:21:45 PM PST US From: "kevinbonds" Subject: RE: Zenith-List: Hat Stiffener Press + Pic of the day Did you engineer this to take into account spring-back (i.e. did you add more angle to the bends)? Kevin Bonds Nashville TN 601XL Corvair powered; Plans building. Empennage done; working on wings and engine. http://home.comcast.net/~kevinbonds do not archive DO NOT ARCHIVE _____ [mailto:owner-zenith-list-server@matronics.com] On Behalf Of Debo Cox Sent: Friday, July 28, 2006 7:52 AM After a few failed attempts at making hat stiffeners for the main spar, I decided to try making a press die for them in much the same way I made my flanging dies. Here's what I came up with. I used the same timbertech composite material as I used for the flanging dies, and was able to fabricate the whole set using a table saw and some 5-minute epoxy from ACE hardware. I rounded all of the corners to the proper radius, and epoxied the male 45-degree press flange to the top die. To use them, I put a piece of .025 between the dies and put them under pressure with the shop press until the bend is formed, then trim the flanges to the proper size. Out comes perfectly shaped, high-quality, repeatable hat stiffeners lookin' like the factory made 'em. Debo Cox Nags Head, NC XL/Corvair Moving slow, but still moving (which is good) ________________________________ Message 27 ____________________________________ Time: 12:49:52 PM PST US From: "Randy Bryant" Subject: Re: Zenith-List: Coomposite Gear Hi Kevin, You are right about the weight... The current weight of the XL gear is rediculous at over 40 lbs... BUT, nevertheless, I'm building my own main gear as well... I have a 12' X 3/4" X 8" piece of 6061-T6 now to make it from... It's still under my table and I've not started on it... I have a friend who has a 150 ton press that should make small work of the cold bends on the gear... Am I right in assuming the composite gear from AS weighs 2.45Kg, which is about 5.5lbs??? If so, I may be thinking of going the same route as you... This is one heck of a way to save weight... Thanks, Randy XL - Wings - Plans Only http://www.n344rb.com Do Not Archive ----- Original Message ----- From: kevinbonds To: zenith-list@matronics.com Sent: Friday, July 28, 2006 2:50 PM Subject: Zenith-List: Coomposite Gear I can't make up my mind about what gear to use on my XL. I began fabrication the necessary parts for the Composite gear from AS tonight, but began to worry about the longevity of a Composite structure for landing gear. I don't want to have to worry about the gear beginning to crack in the future. I don't know if I'll be able to find a replacement 10-15 years from now. The pluses are 1) it would save a ton of weight. 2) it would save a ton of weight. The minuses are 1) increase in complexity 2) more time 3) slightly more expensive 4) wont be easily converted back to standard gear if needed 5) How long will it last? I would benefit from some discussion on the topic. Does anyone have anything to add? Kevin Bonds Nashville TN 601XL Corvair powered; Plans building. Empennage done; working on wings and engine. http://home.comcast.net/~kevinbonds do not archive DO NOT ARCHIVE ________________________________ Message 28 ____________________________________ Time: 12:49:59 PM PST US From: Gary Gower Subject: Re: Zenith-List: Re: Firewall rivets The Firewall rivets put out 180 hp? DJ45 I will sure want one of those rivets for my next project :-) :-) :-) Do not Archive !!!!! Saludos Gary Gower. dj45 wrote: --> Zenith-List message posted by: "dj45" It puts out 180 hp. They have a rather informative web site. I have spent a lot of time on this choice. I belive it is the way to go for what we want to use the plane for --------------------------------- Next-gen email? Have it all with the all-new Yahoo! Mail Beta. ________________________________ Message 29 ____________________________________ Time: 01:05:02 PM PST US From: NYTerminat@aol.com Subject: Re: Zenith-List: Coomposite Gear Kevin I am thinking about ordering the composite gear for my CH-701 Bob Spudis a message dated 7/28/2006 3:52:11 P.M. Eastern Daylight Time, randy@shadycreekoutlaws.com writes: Hi Kevin, You are right about the weight... The current weight of the XL gear is rediculous at over 40 lbs... BUT, nevertheless, I'm building my own main g ear as well... I have a 12' X 3/4" X 8" piece of 6061-T6 now to make it from... It's still under my table and I've not started on it... I have a friend wh o has a 150 ton press that should make small work of the cold bends on the ge ar... Am I right in assuming the composite gear from AS weighs 2.45Kg, which is about 5.5lbs??? If so, I may be thinking of going the same route as you... This is one heck of a way to save weight... Thanks, Randy XL - Wings - Plans Only _http://www.n344rb.com_ (http://www.n344rb.com/) Do Not Archive ----- Original Message ----- Sent: Friday, July 28, 2006 2:50 PM I can=99t make up my mind about what gear to use on my XL. I began fa brication the necessary parts for the Composite gear from AS tonight, but began to worry about the longevity of a Composite structure for landing gear. I don =99t want to have to worry about the gear beginning to crack in the future. I do n=99t know if I=99ll be able to find a replacement 10-15 years from now. Th e pluses are 1) it would save a ton of weight. 2) it would save a ton of weight. The minuses are 1) increase in complexity 2) more time 3) slightly more expensi ve 4) wont be easily converted back to standard gear if needed 5) How long will i t last? I would benefit from some discussion on the topic. Does anyone have anything to add? Kevin Bonds Nashville TN 601XL Corvair powered; Plans building. Empennage done; working on wings and engine. _http://home.comcast.net/~kevinbonds_ (http://home.comcast.net/~kevinbonds) do not archive DO NOT ARCHIVE ________________________________ Message 30 ____________________________________ Time: 01:15:37 PM PST US From: "Dave Ruddiman" Subject: Re: Zenith-List: Re: Firewall rivets What's the story on the Delta Hawk diesel? I looked on their website to find a price. Anyone know how much it is? Dave in Salem 801 without an engine yet, but not ready anyway. ----- Original Message ----- From: Gary Gower To: zenith-list@matronics.com Sent: Friday, July 28, 2006 12:48 PM Subject: Re: Zenith-List: Re: Firewall rivets The Firewall rivets put out 180 hp? DJ45 I will sure want one of those rivets for my next project :-) :-) :-) Do not Archive !!!!! Saludos Gary Gower. dj45 wrote: --> Zenith-List message posted by: "dj45" It puts out 180 hp. They have a rather informative web site. I have spent a lot of time on this choice. I belive it is the way to go for what we want to use the plane for ________________________________ Message 31 ____________________________________ Time: 01:26:09 PM PST US From: Tom Henderson Subject: Zenith-List: Ch 620 --- MIME Errors - No Plain-Text Section Found --- A message with no text/plain MIME section was received. The entire body of the message was removed. Please resend the email using Plain Text formatting. HOTMAIL is notorious for only including an HTML section in their client's default configuration. If you're using HOTMAIL, please see your email application's settings and switch to a default mail option that uses "Plain Text". --- MIME Errors No Plain-Text Section Found --- ________________________________ Message 32 ____________________________________ Time: 02:45:48 PM PST US From: Debo Cox Subject: RE: Zenith-List: Hat Stiffener Press + Pic of the day Hi Kevin, Thanks for the kind words. I've used your web site for inspiration and ideas a lot - so right back atcha. I didn't add any angle for springback, and haven't found any to really be necessary. I suppose it's because the part is being pressed out under pressure, but it doesn't seem to be a factor - at least with mine. I'm not sure if it was just dumb luck, or my, uh, "engineering", but I suspect the first one. The whole setup was really easy to make - took less than an hour, and I even screwed up a couple pieces of material trying to get the dimensions right. The first ones I tried to make on my brake were a disaster, so this seemed like a workable alternative. I've made a complete set for the right wing so far, and it's so far, so good. Debo Cox Nags Head, NC XL/Corvair do not archive --------------------------------- Yahoo! Music Unlimited - Access over 1 million songs.Try it free. ________________________________ Message 33 ____________________________________ Time: 03:01:05 PM PST US From: Crvsecretary@aol.com Subject: Re: Zenith-List: Ch 620 Hello Tom: I remember reading a magazing interview with CH where he said (paraphrasing here....)... the lack of a lightweight aero-powerplant that would accept a full-feathering prop put the Gemini as a very low priority. The prototype has an engine-out climb rate that was almost non-existant. The drag of the stopped prop was just too much to overcome. Please don't ask me to reference the article - it has been lost to the dross within my own overburdened grey matter...... Tracy Smith Naugatuck, CT 601xl N458XL (reserved) working on wings do not archive In a message dated 7/28/2006 4:27:54 PM Eastern Standard Time, admin@arachnidrobotics.com writes: This may be a bit early, seeing as how I'm not yet done with my 601XL, but has anyone heard any further info on the Gemini 620? I understand that it's been put on the back burner, but is it still simmering or has it died? ________________________________ Message 34 ____________________________________ Time: 04:10:13 PM PST US From: "dj45" Subject: Zenith-List: Re: Firewall rivets --> Zenith-List message posted by: "dj45" Thanks for the input. I ordered SS rivets today. Makes sense to me, if I had just stoped to think about it. As for the other post, I would be more than happy to give you the extra rivets if you need the extra HP :>) Read this topic online here: http://forums.matronics.com/viewtopic.php?p=50421#50421 ________________________________ Message 35 ____________________________________ Time: 04:13:45 PM PST US From: LarryMcFarland Subject: Re: Zenith-List: strut coating --> Zenith-List message posted by: LarryMcFarland Scott, Jeff and Ron, I really do like the chromed appearance, but I still sport the larger wheel/tire combination and on landing/braking and turning the larger diameter tires and wheels put considerable more stress on thin gear strut plates. I've saved the images of Ron's gusset approach and consider it a really solid solution which could possibly be chromed after. Will look closer as painting progresses. Thanks for the ideas. Larry McFarland N5SL wrote: >--> Zenith-List message posted by: N5SL > >I had my rudder pedals, steps and gear leg chromed >last February and I really like the results. Before: >http://www.cooknwithgas.com/2_02_05_PlatingParts.jpg >After: >http://www.cooknwithgas.com/2_19_05_Nosewheel.jpg >http://www.cooknwithgas.com/2_19_05_Pedals.jpg > > >Scott Laughlin >Omaha, Nebraska >601XL - Canopy complete! > >--- Jeff Small wrote: > > >>Mine has held nicely on three gear legs (HDS) for >>four years. >> >>CAVU jeff >> >> > > > > > > > > > ________________________________ Message 36 ____________________________________ Time: 04:35:43 PM PST US From: VideoFlyer@aol.com Subject: Re: Zenith-List: Firewall rivets <<<<>> The firewall is steel...either galvanized or stainless. But the "L" braces and the channels are aluminum. Aren't those dissimilar metals? What's the difference between aluminum rivets in stainless steel...and stainless rivets in aluminum? Dave ________________________________ Message 37 ____________________________________ Time: 04:57:14 PM PST US From: Monty Graves Subject: RE: Zenith-List: Hat Stiffener Press + Pic of the day --> Zenith-List message posted by: Monty Graves These really are a nice set of dies Debo.. I hadn't thought of using the plastic deck material.... This type of die would also work for a lot of other things too. Like the relief beads on the gas tanks..... fair lead pieces for cables, and might even work for the hat stiffeners on the floor pan of the 701. I wish I had seen your dies, before I purchased mine for the 701 Monty Graves At 02:41 PM 7/28/2006 -0700, you wrote: >Hi Kevin, > >Thanks for the kind words. I've used your web site for inspiration and >ideas a lot - so right back atcha. > >I didn't add any angle for springback, and haven't found any to really be >necessary. I suppose it's because the part is being pressed out under >pressure, but it doesn't seem to be a factor - at least with mine. I'm not >sure if it was just dumb luck, or my, uh, "engineering", but I suspect the >first one. > >The whole setup was really easy to make - took less than an hour, and I >even screwed up a couple pieces of material trying to get the dimensions >right. The first ones I tried to make on my brake were a disaster, so this >seemed like a workable alternative. I've made a complete set for the right >wing so far, and it's so far, so good. > >Debo Cox >Nags Head, NC >XL/Corvair > ________________________________ Message 38 ____________________________________ Time: 05:06:37 PM PST US From: ihab.awad@gmail.com Subject: Re: Zenith-List: Hat Stiffener Press + Pic of the day --> Zenith-List message posted by: ihab.awad@gmail.com On 7/28/06, Monty Graves wrote: > These really are a nice set of dies Debo.. I hadn't thought of using the > plastic deck material.... This type of die would also work for a lot of > other things too. Yup ... purely speculating, I would say this general technique could probably be used to make very clean joggles on longerons by making male and female forms that cuddle the angle securely on all sides with sheetmetal shims glued to the faces to do the joggling. -- Ihab -- Ihab A.B. Awad, Palo Alto, CA ________________________________ Message 39 ____________________________________ Time: 05:54:55 PM PST US From: ron dewees Subject: Re: Zenith-List: strut coating --> Zenith-List message posted by: ron dewees ron dewees wrote: >> Hi Larry, >> Thanks for the comments. I got no feedback and wasn't sure the pix >> got attached to the post. FWIW my gear legs were nickel plated, I >> was told by the guy I got the project from. I only have 140 hours on >> the legs so can't say they will last forever or not, but they take >> the bounces of a turf strip just fine. I also made a nylon plate >> with a hole in it to act as a bearing inside the upper strut mount on >> the wing but am not sure it's a cure all for dirt or wear. My plane >> is a taildragger so it gets possibly more weight per gear in a >> landing than a tri gear model.. The bungees are holding up just fine >> and it still sits at the same "neutral" spot as when I first hung the >> motor >> I took a good look at the ZAC welded plate at the strut and the >> weld is beautiful, but perhaps a little shallow. Jim Pellen's 601HD >> that lost a gear leg failed at the weld, altho a thicker plate than >> our 1/8 inch may have helped, or at least encouraged the welder to >> lay a thicker bead on the joint. I used aprox 3/16" angle iron from >> a bed rail to make the gussets and put a heavier bead on the pieces >> so I think it will strengthen the whole area. Time will tell. I >> don't see any reason why the whole strut couldn't be plated if you >> want to. It's all steel. I just sprayed mine with zinc chromate and >> a silver primer that matches the gear legs. >> Good luck. >> Ron >> >> LarryMcFarland wrote: >> >>> --> Zenith-List message posted by: LarryMcFarland >>> >>> >>> Scott, Jeff and Ron, >>> I really do like the chromed appearance, but I still sport the >>> larger wheel/tire combination and on landing/braking and turning the >>> larger >>> diameter tires and wheels put considerable more stress on thin gear >>> strut plates. I've saved the images of Ron's gusset approach and >>> consider it a really solid solution which could possibly be chromed >>> after. Will look closer as painting progresses. Thanks for the >>> ideas. >>> >>> Larry McFarland >>> >>> > ________________________________ Message 40 ____________________________________ Time: 07:18:30 PM PST US From: ron dewees Subject: Re: Zenith-List: strut coating --> Zenith-List message posted by: ron dewees Correction to my last post-- It was Jim Olson's HD that lost a gear leg and not Jim Pellen. Ron do not archive ron dewees wrote: > --> Zenith-List message posted by: ron dewees > > ron dewees wrote: > ________________________________ Message 41 ____________________________________ Time: 07:28:26 PM PST US From: "Ashcraft, Keith -AES" Subject: RE: Zenith-List: Ch 620 I seem to remember the same information as Tracy. With the lack of obtaining a min. of 100fpm climb rate with one engine, has put the desing at a low priority. Keep pulling rivets everybody!!!! or for those of you flying, keep "us builder's", HOPES UP!!!! Keith **************************************************************** -----Original Message----- Crvsecretary@aol.com Sent: Fri 7/28/2006 3:58 PM Hello Tom: I remember reading a magazing interview with CH where he said (paraphrasing here....)... the lack of a lightweight aero-powerplant that would accept a full-feathering prop put the Gemini as a very low priority. The prototype has an engine-out climb rate that was almost non-existant. The drag of the stopped prop was just too much to overcome. Please don't ask me to reference the article - it has been lost to the dross within my own overburdened grey matter...... Tracy Smith Naugatuck, CT 601xl N458XL (reserved) working on wings do not archive In a message dated 7/28/2006 4:27:54 PM Eastern Standard Time, admin@arachnidrobotics.com writes: This may be a bit early, seeing as how I'm not yet done with my 601XL, but has anyone heard any further info on the Gemini 620? I understand that it's been put on the back burner, but is it still simmering or has it died? ************************************ This e-mail and any files transmitted with it are proprietary and intende d solely for the use of the individual or entity to whom they are addressed. If yo u have received this e-mail in error please notify the sender. Please note that any views or opinions presented in this e-mail are solely those of the author and d o not necessarily represent those of ITT, Inc. The recipient should check this e-mail and any attachments for the presence of viruses. ITT accepts no liability for any damage caused by any virus transmitted by this e-mai l. ************************************ ________________________________ Message 42 ____________________________________ Time: 07:38:40 PM PST US From: "George Swinford" Subject: Zenith-List: Plating Zodiac landing gear I remember from my days as a Boeing engineer that 4130N steel is not subject to embrittlement from plating, but I don't have access to the material and process handbooks anymore to be sure about it. Maybe someone on the list can can put their hands on this kind of information and clear the issue up. Anybody...? George Do not archive ________________________________ Message 43 ____________________________________ Time: 07:44:49 PM PST US From: "Ron Lendon" Subject: Zenith-List: Re: Hat Stiffener Press + Pic of the day --> Zenith-List message posted by: "Ron Lendon" Debo, You are the master. I had someone offer to buy my flanging dies the other day, which I declined, and I refered him to your pics. You might wanna take a look at how I solved bending the flaps. The final 163 degree bend was done with the 200lb gravity actuated stomp press [Laughing] -------- Ron Lendon, Clinton Township, MI Corvair Zodiac XL, ScrapBuilder ;-) Read this topic online here: http://forums.matronics.com/viewtopic.php?p=50463#50463 ________________________________ Message 44 ____________________________________ Time: 07:56:05 PM PST US From: "Ron Lendon" Subject: Zenith-List: Re: Coomposite Gear --> Zenith-List message posted by: "Ron Lendon" Kevin, Not sure if it's the same material, but GM and other auto mfgs. have been using composites for leaf springs for quite some time now. Not real sure how long but I bet they have some data. Many of the commercial vehicles must run 250k miles with out major suspension problems. FWIW -------- Ron Lendon, Clinton Township, MI Corvair Zodiac XL, ScrapBuilder ;-) Read this topic online here: http://forums.matronics.com/viewtopic.php?p=50466#50466 ________________________________ Message 45 ____________________________________ Time: 08:49:52 PM PST US From: "kevinbonds" Subject: RE: Zenith-List: Coomposite Gear Randy wrote: < Am I right in assuming the composite gear from AS weighs 2.45Kg, which is about 5.5lbs??? If so, I may be thinking of going the same route as you... This is one http://home.comcast.net/~kevinbonds do not archive DO NOT ARCHIVE Am I right in assuming the composite gear from AS weighs 2.45Kg, which is about 5.5lbs??? If so, I may be thinking of going the same route as you... This is one heck of a way to save weight... Thanks, Randy XL - Wings - Plans Only http://www.n344rb.com Do Not Archive ----- Original Message ----- Sent: Friday, July 28, 2006 2:50 PM I can't make up my mind about what gear to use on my XL. I began fabrication the necessary parts for the Composite gear from AS tonight, but began to worry about the longevity of a Composite structure for landing gear. I don't want to have to worry about the gear beginning to crack in the future. I don't know if I'll be able to find a replacement 10-15 years from now. The pluses are 1) it would save a ton of weight. 2) it would save a ton of weight. The minuses are 1) increase in complexity 2) more time 3) slightly more expensive 4) wont be easily converted back to standard gear if needed 5) How long will it last? I would benefit from some discussion on the topic. Does anyone have anything to add? Kevin Bonds Nashville TN 601XL Corvair powered; Plans building. Empennage done; working on wings and engine. http://home.comcast.net/~kevinbonds do not archive DO NOT ARCHIVE ________________________________ Message 46 ____________________________________ Time: 08:53:19 PM PST US From: "David X" Subject: Zenith-List: Re: Rotax 912 Tachometer Problems --> Zenith-List message posted by: "David X" I can't speak for others, but I use "DO NOT ARCHIVE" because of what happened to a late friend of mine who was killed in a Zodiac. The newspapers quoted all sorts of things out of context about him and thus maligning him, home-builds and experimentals in general. It seems that they got the info from an archive of this forum. 321PT wrote: > Am I missing something?? You guys have some good info on problems, so why would you put "Do not archive" on your messages?? Being an old fart, I am not going to be able to remember all this info on the top of my head.? Doesn't the DNA stop anyone from finding it later? > Or maybe I just don't understand all this new fangled stuff. > ? -------- Zodiac 601 XL - CZAW Built - Rotax 912S DO NOT ARCHIVE Read this topic online here: http://forums.matronics.com/viewtopic.php?p=50474#50474 ________________________________ Message 47 ____________________________________ Time: 09:06:28 PM PST US From: "David X" Subject: Zenith-List: Re: Coomposite Gear --> Zenith-List message posted by: "David X" So there is some sort of retrofit required - i.e. not a straight replacement for gear on an existing 601? Kevin Bonds wrote: > Thats my understanding. Of course there will be a couple of pounds worth of stiffening that will need to be done. The Center channel needs to be made of .040 instead of .032 and slightly different dimensions as well as some stiffeners under the armrest area etc. -------- Zodiac 601 XL - CZAW Built - Rotax 912S DO NOT ARCHIVE Read this topic online here: http://forums.matronics.com/viewtopic.php?p=50476#50476 ________________________________ Message 48 ____________________________________ Time: 09:40:33 PM PST US From: "David X" Subject: Zenith-List: Re: Night VFR with a Rotax --> Zenith-List message posted by: "David X" I'd be interested in knowing the answer you get from EAA, but I beleive it applies specifically to SLSA and not ELSA or experimental. It has to do with the fact that regs reguarding SLSA are more like those for standard category airworthiness rules; which makes sense because SLSA can be flown for hire. FAR 91.327 specifically applies to SLSA (paragraph D is of particular interest). See http://www.sportpilot.org/news/051013_ifr.html -------- Zodiac 601 XL - CZAW Built - Rotax 912S DO NOT ARCHIVE Read this topic online here: http://forums.matronics.com/viewtopic.php?p=50480#50480 ________________________________ Message 49 ____________________________________ Time: 10:03:07 PM PST US From: "TxDave" Subject: Zenith-List: Re: Coomposite Gear --> Zenith-List message posted by: "TxDave" Kevin, There was a post on June 2nd by a plans builder from the UK named Malcom Hunt. He says the composite gear are required there. Maybe he can address your concerns. Dave Clay Temple, TX 601XL scratch builder Read this topic online here: http://forums.matronics.com/viewtopic.php?p=50483#50483 ________________________________ Message 50 ____________________________________ Time: 10:12:40 PM PST US From: "David X" Subject: Zenith-List: Re: Weight & Balance --> Zenith-List message posted by: "David X" My CG attached. Also attached spreadsheet to help work out CG cenarios. I don't care what anyone from Zenair says the standard motor mount that you get for the 912 is flawed as far as CG is concerned. Hey, I can do the grade-school math as well as the next guy. To solve the problem, I had a special mount and cowling made by CZAW to move the 912 engine forward 4 additional inches from original design. The empty CG is now 12", which is so/so. It was more than 14" with the standard mount; which is awful. It aught to be more like 10 but the nose would be too long at 10 CG and would interfere with visibility. Im toying with the idea of using the composite gear; which should improve the CG and useful load at the same time. dfmoeller wrote: > Does anyone have a good sample (meaning realistic) of a W&B sheet for a 601XL with Rotax 912ULS? And can you scan it and send to me? I'm trying to get a sanity check on my numbers. -------- Zodiac 601 XL - CZAW Built - Rotax 912S DO NOT ARCHIVE Read this topic online here: http://forums.matronics.com/viewtopic.php?p=50484#50484 Attachments: http://forums.matronics.com//files/wb_601xl_675.xls http://forums.matronics.com//files/xl_wb_156.pdf ________________________________ Message 51 ____________________________________ Time: 10:33:25 PM PST US From: "Ron Lendon" Subject: Zenith-List: Olfa Knife Cutting Nose Ribs --> Zenith-List message posted by: "Ron Lendon" Hey all, I just had a pleasant experience cutting and breaking .025 aluminum. I have done it only on straight lines but tonight I cut 14 nose ribs and deburred them in about two hours. The trick it seems is to cut rectangular blanks close to the finished size, that I did in a shear, then score the shape with the P-800 Olfa Knife about 10 times. I just took my time and didnt press real hard. Blank size was 10 X 14. Had to be real careful lining up the forming block to make sure it was centered on the 10 dimension. Transferred the holes, drilled em, bolted template to the blank and scored away. I used flanging pliers to grab the edge and get things started but it broke away clean. Be sure to wear gloves. Pics on mykitlog web site. -------- Ron Lendon, Clinton Township, MI Corvair Zodiac XL, ScrapBuilder ;-) Read this topic online here: http://forums.matronics.com/viewtopic.php?p=50486#50486 ________________________________ Message 52 ____________________________________ Time: 10:45:22 PM PST US From: "David X" Subject: Zenith-List: Re: Coomposite Gear --> Zenith-List message posted by: "David X" Thanx. Yes - retrofit required. TxDave wrote: > There was a post on June 2nd by a plans builder from the UK named Malcom Hunt. He says the composite gear are required there. Maybe he can address your concerns. -------- Zodiac 601 XL - CZAW Built - Rotax 912S DO NOT ARCHIVE Read this topic online here: http://forums.matronics.com/viewtopic.php?p=50488#50488 ________________________________ Message 53 ____________________________________ Time: 11:41:25 PM PST US From: Gary Gower Subject: Re: Zenith-List: Firewall rivets There has been some posts about this "discimilar metals" danger of corrosion... It beguin when I told the list about the SS firewall we built for my 701... I cant remember what the final results of this tread were... Probably the plane will fall apart because of corrosion in 250 years :-) :-) Just in case, to be on the safe side, I put some Zinc Chromate in a little cup and wetted each rivet in the firewall before installing and pulling, also double checked that we painted the touching parts with plenty ZC, Hope it holds the next 25 plus years I think I will be able to continue flying... :-) Saludos Gary Gower Flying from Chapala, Mexico. 701 912S 601 XL in progress... VideoFlyer@aol.com wrote: <<<<>> The firewall is steel...either galvanized or stainless. But the "L" braces and the channels are aluminum. Aren't those dissimilar metals? What's the difference between aluminum rivets in stainless steel...and stainless rivets in aluminum? Dave --------------------------------- Next-gen email? Have it all with the all-new Yahoo! Mail Beta. ________________________________ Message 54 ____________________________________ Time: 11:53:09 PM PST US From: Gary Gower Subject: Re: Zenith-List: Rotax 912 Tach Problems now News people... David, Dont bother for that, Newspaper are the same all over the world. Here we have a saying: "Does not matter if they talk good or bad things about me, at least they know I am here..." They have to sell the paper, so they write in the edge of ethics all the time. Saludos Gary Gower Do not archive (just in case) :-) David X wrote: --> Zenith-List message posted by: "David X" I can't speak for others, but I use "DO NOT ARCHIVE" because of what happened to a late friend of mine who was killed in a Zodiac. The newspapers quoted all sorts of things out of context about him and thus maligning him, home-builds and experimentals in general. It seems that they got the info from an archive of this forum. 321PT wrote: > Am I missing something?? You guys have some good info on problems, so why would you put "Do not archive" on your messages?? Being an old fart, I am not going to be able to remember all this info on the top of my head.? Doesn't the DNA stop anyone from finding it later? > Or maybe I just don't understand all this new fangled stuff. > ? -------- Zodiac 601 XL - CZAW Built - Rotax 912S DO NOT ARCHIVE --------------------------------- How low will we go? Check out Yahoo! Messengers low PC-to-Phone call rates.