---------------------------------------------------------- Zenith-List Digest Archive --- Total Messages Posted Tue 05/08/07: 16 ---------------------------------------------------------- Today's Message Index: ---------------------- 1. 06:38 AM - wing walk material (LarryMcFarland) 2. 08:07 AM - Re: wing walk material (Tim Juhl) 3. 12:54 PM - Fw: Landing gear (wade jones) 4. 01:18 PM - Day one (Jerry Hey) 5. 02:24 PM - Re: Day one (Jerry Hey) 6. 02:24 PM - Re: Day one (Carlos Sa) 7. 02:25 PM - Corvair Mount (Jaybannist@cs.com) 8. 02:39 PM - Re: Corvair Mount (Gig Giacona) 9. 02:47 PM - Re: Corvair Mount (Craig Payne) 10. 03:46 PM - Re: Propellor leading edge tape (Jeffrey J Paris) 11. 03:57 PM - Corvair Mount (Jaybannist@cs.com) 12. 04:34 PM - Re: Re: wing walk material (LarryMcFarland) 13. 04:37 PM - Re: Day one (Paul Mulwitz) 14. 07:02 PM - Corvair Engine (Jeyoung65@aol.com) 15. 08:00 PM - Welding 601XL Fuel Tanks (Ron Lendon) 16. 08:56 PM - Re: Distance of Left and Right wing to rear reference point (eddies) ________________________________ Message 1 _____________________________________ Time: 06:38:57 AM PST US From: LarryMcFarland Subject: Zenith-List: wing walk material Hi guys, I took Jeff Smalls advice and purchased some wing walk material from Ray Allen Company. The material deserves a second look by anyone wishing there were a better wing walk material than what looks and feels like roofing shingles. After cutting it to size and rounding off the corners, I placed it exactly where it needed to be. Daughter Sara picked up 6-inches of the forward end and separated the peel- off material, cut off the excess peel strip and folded corners each side at the cut and I pushed the material down while continuing to hold position for the lower half. When the front portion was stuck down, the rear portion was lifted and peel strip corners were pulled to separate the peel off material. I worked to spread the contact area back to the other end. Two rows of rivets were underneath this material and a pin prick near each rivet allowed the air to be removed. A 5/16 nylock nut was used to push the material down around each rivet. The whole operation for both wings was done in about 30-minutes. Thanks Jeff, this material is exactly what I was looking for and the finish is non-skid without the associated loose grit. Larry McFarland 601HDS at www.macsmachine.com ________________________________ Message 2 _____________________________________ Time: 08:07:06 AM PST US Subject: Zenith-List: Re: wing walk material From: "Tim Juhl" How about a nice close up picture? Tim -------- DO NOT ARCHIVE ______________ CFII Champ L16A flying Zodiac XL - Jabiru 3300A Working on wings Read this topic online here: http://forums.matronics.com/viewtopic.php?p=111581#111581 ________________________________ Message 3 _____________________________________ Time: 12:54:03 PM PST US From: "wade jones" Subject: Zenith-List: Fw: Landing gear Wade Jones South Texas 601XL plans building Cont. 0200 ----- Original Message ----- From: wade jones Sent: Friday, May 04, 2007 8:59 AM Subject: Landing gear Hello ,could you quote me a price of the 601XL complete landing gear. I have already installed the brake cylinders and the nose gear leg including the top & bottom bearings. I need a quote excluding the parts already installed . Thanks Plans holder #6464 Wade Jones South Texas 601XL plans building Cont. 0200 ________________________________ Message 4 _____________________________________ Time: 01:18:41 PM PST US From: Jerry Hey Subject: Zenith-List: Day one Hi guys, I promise I won't load this list up with every little move but today I ordered my first sheet of Aluminum (4' x 8' x .025") and built a hole flanging tool. The tool cost about $3.50. I have nothing to try it on, but here it is. I am scratch building but might buy a part or two if the going gets too tough. I plan to cut 2' x 4' off the sheet I just ordered to use for practice. Question, How critical are the diameters of the lightening holes? I can buy hole saws that are quite close in size but not exact. Morse offers saws in 1/8" increments. Thanks, Jerry Hey STOL 701 ________________________________ Message 5 _____________________________________ Time: 02:24:39 PM PST US From: Jerry Hey Subject: Re: Zenith-List: Day one Looking further at the Morse site, I found they had metric hole saws in all the sizes needed. I ordered 65mm, 95mm and 114mm. Jerry On May 8, 2007, at 4:15 PM, Jerry Hey wrote: > Hi guys, I promise I won't load this list up with every little > move but today I ordered my first sheet of Aluminum (4' x 8' x . > 025") and built a hole flanging tool. The tool cost about $3.50. > I have nothing to try it on, but here it is. > > I am scratch building but might buy a part or two if the going > gets too tough. I plan to cut 2' x 4' off the sheet I just ordered > to use for practice. > > Question, How critical are the diameters of the lightening > holes? I can buy hole saws that are quite close in size but not > exact. Morse offers saws in 1/8" increments. Thanks, > > Jerry Hey > STOL 701 > ________________________________ Message 6 _____________________________________ Time: 02:24:39 PM PST US From: "Carlos Sa" Subject: Re: Zenith-List: Day one Welcome aboard, Jerry About the lightening wholes, I would ask ZAC - I guess a small variation is ok, but you need to check. They blessed a change I made on that "department". As for cutting the holes, wouldn't a single fly cutter be cheaper instead of multiple hole saws? Good luck Carlos CH601-HD, plans Montreal, Canada On 08/05/07, Jerry Hey wrote: > > Hi guys, I promise I won't load this list up with every little move > but today I ordered my first sheet of Aluminum (4' x 8' x .025") and > built a hole flanging tool. The tool cost about $3.50. I have > nothing to try it on, but here it is. > > I am scratch building but might buy a part or two if the going > gets too tough. I plan to cut 2' x 4' off the sheet I just ordered to > use for practice. > > Question, How critical are the diameters of the lightening holes? > I can buy hole saws that are quite close in size but not exact. > Morse offers saws in 1/8" increments. Thanks, > > Jerry Hey > STOL 701 > > ________________________________ Message 7 _____________________________________ Time: 02:25:56 PM PST US From: Jaybannist@cs.com Subject: Zenith-List: Corvair Mount Corvair Guys: I finally received a motor mount from WW today. I tried to fit it up to the mounting bolts and found that the bolts won't go through the spool pieces. Are they supposed to be driven; or are the tubes supposed to be reamed for a fit? Jay in Dallas ________________________________ Message 8 _____________________________________ Time: 02:39:07 PM PST US Subject: Zenith-List: Re: Corvair Mount From: "Gig Giacona" When I mounted mine all it took was a light to medium tap with a rubber mallet. Will the bolts of the same size slide into the mount unmounted? Or is it a positioning problem? -------- W.R. "Gig" Giacona 601XL Under Construction See my progress at www.peoamerica.net/N601WR Read this topic online here: http://forums.matronics.com/viewtopic.php?p=111659#111659 ________________________________ Message 9 _____________________________________ Time: 02:47:27 PM PST US From: "Craig Payne" Subject: RE: Zenith-List: Corvair Mount Is it a question of alignment or actual diameter? In other words will a loose bolt fit into the spools? I would *not* force the bolt in. I suspect the problem is a combination of alignment and distortion of the spool during welding. Unfortunately (as you probably know) William is on vacation until the middle of the month. I would do two things: if it won't remove too much metal ream them out so that a free bolt will fit in. Then if there are alignment problems loosen the bolts that hold the motor mount brackets to the longerons, bolt the mount and then retighten the brackets. If you do this you may want to replace the nylon-insert locknuts on the motor mount brackets. -- Craig ________________________________ Message 10 ____________________________________ Time: 03:46:09 PM PST US Subject: RE: Zenith-List: Propellor leading edge tape From: "Jeffrey J Paris" Hello Listers, I have used strips of metal aluminium tape with great success, I have doubled it up on itself and it works great at a very resonable price. Easy to replace too. Jeff Paris N196ZP Jab3300 CH601XL 136 hours of pure fune and enjoyment! --- On Mon 05/07, george may < gfmjr_20@HOTMAIL.COM > wrote: From: george may [mailto: gfmjr_20@HOTMAIL.COM] Subject: RE: Zenith-List: Propellor leading edge tape _______________________________________________ Join Excite! - http://www.excite.com The most personalized portal on the Web! ________________________________ Message 11 ____________________________________ Time: 03:57:20 PM PST US From: Jaybannist@cs.com Subject: Zenith-List: Corvair Mount Corvair Guys, Thanks for the help. I ran a 3/8" drill bit through each of the spool holes. All except one now let the bolt slip all the way through. I think the holes were just "dirty." One still gets tight about three-quarters of the way in. I think that spool tube probably got distorted during welding. I also think that I can get that one installed with just a light amount of force with a rubber hammer. Thanks again for the help Jay in Dallas ________________________________ Message 12 ____________________________________ Time: 04:34:14 PM PST US From: LarryMcFarland Subject: Re: Zenith-List: Re: wing walk material Hi Tim, Just punch up these two links for pictures of the wing walks with the Ray Allen Company material. This is a no grit, textured surface that remains a good non-skid material and would remain easy on the knees and elbows. http://www.macsmachine.com/images/completion/full/wingwalk1.gif http://www.macsmachine.com/images/completion/full/wingwalk2.gif Larry McFarland 601HDS at www.macsmachine.com Tim Juhl wrote: > How about a nice close up picture? > > Tim > > > ________________________________ Message 13 ____________________________________ Time: 04:37:23 PM PST US From: Paul Mulwitz Subject: Re: Zenith-List: Day one Hi Jerry, I am a kit builder, but I have made many small parts for my plane. I guess that qualifies me to make a few comments on your questions. First, on the lightening holes - I am sure 1/8 inch variation is OK. That is within the general distance tolerance for all parts on the design which (if I remember correctly) is specified in the builder's manual as 3 mm. This much variation on lightening holes will be no problem if you bend the flanges with a tool like the one in your picture or a simple stick with a slot cut in it. On the other hand, the hole tolerance must be very tight if you use press dies to make the flanges. Rather than cutting off a 2x4 piece of aluminum for experimenting, I would recommend trying to make some specific parts like perhaps elevator ribs and cut the exact part needed for each attempt. Good luck and welcome to the club. Paul XL fuselage do not archive At 01:15 PM 5/8/2007, you wrote: >Hi guys, I promise I won't load this list up with every little move >but today I ordered my first sheet of Aluminum (4' x 8' x .025") and >built a hole flanging tool. The tool cost about $3.50. I have >nothing to try it on, but here it is. > > I am scratch building but might buy a part or two if the going >gets too tough. I plan to cut 2' x 4' off the sheet I just ordered to >use for practice. > >Question, How critical are the diameters of the lightening holes? >I can buy hole saws that are quite close in size but not exact. >Morse offers saws in 1/8" increments. Thanks, > >Jerry Hey >STOL 701 > > ________________________________ Message 14 ____________________________________ Time: 07:02:46 PM PST US From: Jeyoung65@aol.com Subject: Zenith-List: Corvair Engine I am new to the board but have been reading it for about two years. Building by plans a 601HD I am looking for a Corvair engine in the south-east. DO NOT ARCHIVE" Jerry of GA ************************************** See what's free at http://www.aol.com. ________________________________ Message 15 ____________________________________ Time: 08:00:28 PM PST US Subject: Zenith-List: Welding 601XL Fuel Tanks From: "Ron Lendon" Group, I am please to announce that I have successfully welded and tested for leaks my right fuel tank. The 5mm .032 flange welding was actually very easy once I figured what my problem was, the arc was so small I couldn't see the puddle. What I did was get the strongest reading glasses I could find and found one of the newer Miller Syncrowave welders with Pulse and Balance controls. It just so happens my EAA Tech Consoler has the equipment. Here are the details: Bought some 4043 rod in 1/16 and 3/32 diameters. Set the welder up to Pulse at 2.3 and the Balance 5.0, the amperage goes up to 200 but I kept it dialed down for a maxium of 180. The .032 5mm flanges fuse with only about 27 to 28 amps so a small 1/16 dia 2% thoriated tungsten was used to fuse the metals. First scuff the area to be welded with a stainless wire brush, reserved only for this purpose. The Filler neck flange goes on the inside, tack it first then weld sections making sure to join your welds. If/when you contaminate the tungsten, STOP and clean/grind the tungsten then using the stainless wire brush, scuff the area and start the welding again. Scuff, Tack, Scuff, Weld is the process. The material oxidizes quickly so that is most important. Next assemble the ends and and tack weld every 3-4 inches, scuff, tack, scuff, tack. Once you have the ends and the long flange tacked together, scuff, weld, scuff weld, scuff, weld. I used very little 1/16 filler rod on the seams, it was just to help get the weld started and touch ups. The 3.25 reading glasses made all the difference, the weld puddle was visible. Just watch the puddle and scuff, weld, scuff weld. If/when you stop welding always scuff just before striking the next arc. Just wanted to let you guys know it can be done and it ain't hard if you get the glasses and the right welding equipment. -------- Ron Lendon, Clinton Township, MI Corvair Zodiac XL, ScrapBuilder ;-) http://www.mykitlog.com/rlendon Read this topic online here: http://forums.matronics.com/viewtopic.php?p=111743#111743 ________________________________ Message 16 ____________________________________ Time: 08:56:01 PM PST US Subject: Zenith-List: Re: Distance of Left and Right wing to rear reference point From: "eddies" Hi Gerry Thanks for the reply, I am going to have another go at setting up my wings this weekend, I think that one of my issues might be that the flap control arm is stopping the wing from swinging back far enough, so I will recheck this. For anyone else that interested, I forgot to mention that this is on a 601XL Regards, Eddie Read this topic online here: http://forums.matronics.com/viewtopic.php?p=111750#111750 ------------------------------------------------------------------------------------- Other Matronics Email List Services ------------------------------------------------------------------------------------- Post A New Message zenith-list@matronics.com UN/SUBSCRIBE http://www.matronics.com/subscription List FAQ http://www.matronics.com/FAQ/Zenith-List.htm Web Forum Interface To Lists http://forums.matronics.com Matronics List Wiki http://wiki.matronics.com Full Archive Search Engine http://www.matronics.com/search 7-Day List Browse http://www.matronics.com/browse/zenith-list Browse Digests http://www.matronics.com/digest/zenith-list Browse Other Lists http://www.matronics.com/browse Live Online Chat! http://www.matronics.com/chat Archive Downloading http://www.matronics.com/archives Photo Share http://www.matronics.com/photoshare Other Email Lists http://www.matronics.com/emaillists Contributions http://www.matronics.com/contribution ------------------------------------------------------------------------------------- These Email List Services are sponsored solely by Matronics and through the generous Contributions of its members.