Today's Message Index:
----------------------
 
     1. 03:09 AM - Re: 601xl aeilerons (Paul Mulwitz)
     2. 04:57 AM - Re: CH601XL roll sensitivity & aileron control weight (kevstewart)
     3. 05:35 AM - Test (Bob)
     4. 06:06 AM - Re: CH 650 canning supression angle (Gig Giacona)
     5. 07:43 AM - Re: 601xl aeilerons (Dirk Zahtilla)
     6. 08:21 AM - Corvair College in November (Al Hays)
     7. 09:17 AM - Re: 601xl aeilerons (Brian Wood)
     8. 09:31 AM - Re: 601xl aeilerons (Gig Giacona)
     9. 09:46 AM - Re: 601xl aeilerons (Paul Mulwitz)
    10. 09:57 AM - Re: Re: 601xl aeilerons (Paul Mulwitz)
    11. 10:55 AM - Re: 601xl aeilerons (Jimbo)
    12. 12:44 PM - Re: Re: 601xl aeilerons (jaybannist@cs.com)
    13. 04:51 PM - Re: 601xl aeilerons (Dave Austin)
    14. 05:07 PM - Flanging Dies (Lee Steensland)
    15. 05:19 PM - Re: Flanging Dies (Paul Mulwitz)
    16. 05:31 PM - Re: Flanging Dies (Bill Naumuk)
    17. 07:01 PM - Re: Flanging Dies (Carlos Sa)
    18. 07:51 PM - Re: Flanging Dies (Randy L. Thwing)
    19. 08:20 PM - Re: Flanging Dies (Debo Cox)
    20. 11:02 PM - Re: Flanging Dies (TxDave)
 
 
 
Message 1
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| Subject:  | Re: 601xl aeilerons | 
      
      
      I think you are discussing two different problems rather than one.
      
      The counter balance is probably there to prevent diverging mechanical 
      oscillation, known as flutter, that can destroy the plane.  C. H. 
      designed his ailerons and all the control surfaces so they are not 
      prone to this problem.  If you don't want to take my word for it, and 
      his, this is a wonderful area for extended discussion some other time.
      
      Your point about "Fixing" the heavy ailerons is an interesting 
      one.  It presumes there is something wrong with them the way they 
      are.  I don't agree with this point of view.  Let me explain . . .
      
      The notion that there should be "Harmony" in airplane controls seems 
      to be an idea unrelated to the way real airplanes function and real 
      pilots fly.  It seems to come from people who are better magazine 
      article writers than pilots and nearly always shows up in airplane 
      flight reviews.  This is the notion that all three axis controls 
      should respond with similar movement to the same input 
      forces.  Perhaps this is a big deal for aerobatic planes that get 
      jerked around in the sky, but for most planes it is not even an 
      issue. What is an issue is that the pilot can get the desired 
      aircraft response rather than some arbitrary control stick movement.
      
      All planes respond to force applied to a control input with movement 
      around the indicated axis.  It is this aircraft rotation response to 
      force that is important rather than its response to control 
      movement.  In many planes and many control axes there is no 
      discernable movement at all of the control input device.  This is the 
      case with the Zodiac aileron control.
      
      Of course, the above is just my personal opinion.  I expect there to 
      be disagreement on the harmony point.  To give you a direct answer to 
      your question, I am not aware of anyone redesigning the controls on 
      any Zodiac to allow the stick to move more easily.
      
      Paul
      XL getting close
      do not archive
      
      
      At 10:41 PM 10/22/2008, you wrote:
      >So following todays little flood of mails about the heavy ailerons , 
      >what if any mods have people done to make this easier?.
      >
      >   I flew a Tecnam JF 2002 at the weekend and the ailerons are the 
      > similar but with balance weight extending forward. I wonder why CH 
      > has not put this on and if it could be done so without great modifications.
      >
      >  Kit gets here 27november ........... :)
      
      
Message 2
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| Subject:  | Re: CH601XL roll sensitivity & aileron control weight | 
      
      
      Thanks for all the replies to my query. I should have said that the XL that I flew
      had the aileron hinges fitted and not just the Al skin.
      
      My apologies for using P1 & P2. In the UK P1 refers the pilot's position and P2
      to the co-pilot's position. I know that this isn't strictly true in a single
      crew aircraft.
      
      My initial reaction upon the handling pilot in the LHS passing control to me in
      the RHS was that he had clamped his stick between his knees and this was preventing
      me from moving my stick.
      
      I flew the aircraft back into the circuit for an overhead join and don't remember
      feeling that I couldn't control the aircraft to make the turns in the circuit.
      
      I could do with another flight but this is not practical given that the owner lives
      about 8 hours away and the WX is pretty bad this time of year.
      
      --------
      Recreational pilot flying out of
      EGHD Plymouth, UK.
      
      
      Read this topic online here:
      
      http://forums.matronics.com/viewtopic.php?p 9970#209970
      
      
Message 3
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Message 4
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| Subject:  | Re: CH 650 canning supression angle | 
      
      
      According to the video of the hanger day the standard L-angles are used. I don't
      remember off hand what their thickness is.
      
      --------
      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 9977#209977
      
      
Message 5
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| Subject:  | Re: 601xl aeilerons | 
      
      
      
      > I think you are discussing two different problems rather than one.
      
                        No, not really... Heavy ailerons. Maybe there are 2 
      solutions (or many more).
      
      > The counter balance is probably there to prevent diverging mechanical 
      > oscillation, known as flutter, that can destroy the plane.  C. H. designed 
      > his ailerons and all the control surfaces so they are not prone to this 
      > problem.  If you don't want to take my word for it, and his, this is a 
      > wonderful area for extended discussion some other time.
      
      Sorry to sound argumentative, but the balancing of control surfaces is to 
      releive the control forces required. Just picture a much larger aircraft 
      with the same setup as the XL and you would have a hard time controling the 
      plane at all; and if I'm not mistaken we can discuss this any time we want.
      
      > Your point about "Fixing" the heavy ailerons is an interesting one.  It 
      > presumes there is something wrong with them the way they are.  I don't 
      > agree with this point of view.  Let me explain . . .
      >
      > The notion that there should be "Harmony" in airplane controls seems to be 
      > an idea unrelated to the way real airplanes function and real pilots fly. 
      > It seems to come from people who are better magazine article writers than 
      > pilots and nearly always shows up in airplane flight reviews.
      
      GEES! I guess I never knew I wasn't a REAL pilot! Plus all the certificated 
      planes I have flown (knot realizing that I didn't know how) had quite well 
      balanced controls. Just take a look at the balance weights on a cessna some 
      time. And by the way I have yet to write a magazine article but apparently 
      those who have may want a word...
      
      > This is the notion that all three axis controls should respond with 
      > similar movement to the same input forces.  Perhaps this is a big deal for 
      > aerobatic planes that get jerked around in the sky, but for most planes it 
      > is not even an issue. What is an issue is that the pilot can get the 
      > desired aircraft response rather than some arbitrary control stick 
      > movement.
      
      Maybe you don't think pilot fatigue is an issue but some of us do
      
      > All planes respond to force applied to a control input with movement 
      > around the indicated axis.  It is this aircraft rotation response to force 
      > that is important rather than its response to control movement.  In many 
      > planes and many control axes there is no discernable movement at all of 
      > the control input device.  This is the case with the Zodiac aileron 
      > control.
      
      What th...
      
      > Of course, the above is just my personal opinion.  I expect there to be 
      > disagreement on the harmony point.  To give you a direct answer to your 
      > question, I am not aware of anyone redesigning the controls on any Zodiac 
      > to allow the stick to move more easily.
      
      Well, I am aware of people making mods. There is one XL recently completed 
      at my home airport with push-pull tubes rather than cables. I am not aware 
      of whether or how much improvement this makes as I have not flown that plane 
      but it is certainly part of the multiple solutions to this problem.Also the 
      first plane I built had a similar issue which was very successfully 
      corrected by moving the hinge point on the ailerons to balance the control 
      forces (by the way, this releives the force on every component from the 
      aileron all the way to the pilots shoulder!)
      Dirk Z
      
      >
      > Paul
      > XL getting close
      
      
Message 6
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| Subject:  | Corvair College in November | 
      
      
      Listers,
      William Wynne asked on his post to the CorvAircraft list, that a link  
      be posted to this announcement.  It should interest anyone  
      considering Corvair power for their project, especially folks in the  
      eastern states.  Since I haven't seen it posted by anyone else, and  
      it's coming up real soon, I'm copying his announcement below:
      
      Al Hays
      N5892H & N701GH reserved
      
      Friends,
      
      We've posted an update on our Web site at
      
      _http://FlyCorvair.com/hangar.html_ (http://www.flycorvair.com/ 
      hangar.html)
      
      with all the information for Corvair College #12 to be held Nov. 7-9  
      just
      outside Columbia, S.C.
      
      Although it's short notice, the event has been planned for a long  
      time and  a
      lot of background work has been done. The host of the event is Ed  
      Fisher. Ed
      is a member of this list who is a regular reader but rarely pops up  
      with a
      post.  Anyone with a specific question about the event can certainly  
      write back
      to the  list, and Ed can chime in and cover it for the benefit of those
      planning on  attending. Additionally, list members including Mark  
      Langford, Joe
      Horton and  Dan Weseman are planning on flying in. All of these guys  
      have been to
      previous  Colleges (in Mark's case all the way back to College #1)  
      and can
      share with the  group insight about the experience.
      
      Having these guys cover some of the basic questions will allow us to  
      stay
      focused on filling orders. I have been laying off the Net in recent  
      weeks in
      order to focus more effort on this. I appreciate the patience  
      builders have
      shown. As evidence that we've continually pumped out parts, the  
      update includes
      a photo of Lynn Dingfelder's newly flying Corvair powered 601. The done
      airplanes and a dozen Colleges offer a testimonial to our long-term  
      commitment  to
      helping builders.
      
      I would greatly appreciate it if builders on the KRNet, 601 list, Piet
      discussion group and the Tailwind/Buttercup group would post a link  
      to our  College
      announcement. Although its shorter notice than we'd like, no one needs
      reservations to attend the College, and if we get the word out  
      efficiently, no  one
      will miss the opportunity to have a great time while learning a lot.
      
      Hope to see as many of you there as possible.
      
      Thank  you.
      William Wynne
      5000-18 HWY 17 #247
      Orange Park, FL 32003 USA
      _http://FlyCorvair.com/hangar.html_ (http://www.flycorvair.com/ 
      hangar.html)
      - October Update 2008
      
      
Message 7
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| Subject:  | Re: 601xl aeilerons | 
      
      
      
      >> I think you are discussing two different problems rather than one.
      >
      >                   No, not really... Heavy ailerons. Maybe there are 2  
      > solutions (or many more).
      >
      
      Maybe we are discussing one issue, but we are offering solutions that are  
      designed to address two issues that are quite distinct,  control forces  
      and flutter. There are multiple ways to relieve the control forces,  
      including aerodynamic balance, balance tabs, spring tabs, weights, and  
      some others I can't remember at the moment.
      
      Flutter is a complex phenonemon that is dependant on balance, speed,  
      elasticity, airflow, and probably a host of others that I don't know about  
      (I am no engineer). It is often overcome by use of balance weights, as  
      well as careful engineering.
      
      Brian in Brazil
      
      
Message 8
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| Subject:  | Re: 601xl aeilerons | 
      
      
      [quote="ideaz1(at)sbcglobal.net]Sorry to sound argumentative, but the balancing
      of control surfaces is to 
      releive the control forces required. Just picture a much larger aircraft 
      with the same setup as the XL and you would have a hard time controling the 
      plane at all; ...[/quote]
      
      
      http://members.eaa.org/home/homebuilders/building/controls/Control%20Surface%20Balancing%20in%20Homebuilts.html?
      
      Control Surface Balancing in Homebuilts
      Sport Aviation - 12/96
      By Tony Bingelis
      
      The obvious question comes to mind. Why balance control surfaces? Do they really
      need to be balanced?
      
      Well, much seems to depend on the original design and construction of the control
      surfaces. Well-designed, rigid structures with little or no play in the hinges,
      control linkages, and trim tabs are less likely to be susceptible to flutter,
      hence, may not need to be statically balanced.
      
      --------
      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=210008#210008
      
      
Message 9
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  | 
      
      
| Subject:  | Re: 601xl aeilerons | 
      
      
      Hi Brian,
      
      Thank you for your comment.  I think your point of view is very 
      valuable.  These issues are related but only distant relatives.
      
      This thread started as a discussion of heavy aileron forces on a demo 
      flight.  The counterbalances were added as a possible solution for 
      the heavy controls.  My last comment was to try to separate the 
      counterbalances from the heavy controls, but your take on this issue 
      seems like it is more clear.
      
      I want to try again to distinguish the heavy control issues without 
      regard to flutter.
      
      If you move the stick left and right on the ground, it takes a 
      significant amount of force to go from one limit to the other.  I 
      submit this is a minor issue.
      
      In the air, when you apply a side force to the stick the plane rolls 
      very nicely.  However, the stick doesn't move much at all in this 
      case.  For a pilot who gets his control feedback from the plane's 
      roll attitude this is not an issue.  For a different pilot who 
      ignores the plane's attitude and only considers how far the control 
      stick moves this is a problem.  I submit that a pilot should gauge 
      his actions by the response of the plane's attitude rather than the 
      movement of the stick.
      
      Best regards,
      
      Paul
      XL getting close
      do not archive
      
      At 09:17 AM 10/23/2008, you wrote:
      >>>I think you are discussing two different problems rather than one.
      >>
      >>                   No, not really... Heavy ailerons. Maybe there are 2
      >>solutions (or many more).
      >
      >Maybe we are discussing one issue, but we are offering solutions that are
      >designed to address two issues that are quite distinct,  control forces
      >and flutter. There are multiple ways to relieve the control forces,
      >including aerodynamic balance, balance tabs, spring tabs, weights, and
      >some others I can't remember at the moment.
      >
      >Flutter is a complex phenonemon that is dependant on balance, speed,
      >elasticity, airflow, and probably a host of others that I don't know about
      >(I am no engineer). It is often overcome by use of balance weights, as
      >well as careful engineering.
      >
      >Brian in Brazil
      
      
Message 10
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  | 
      
      
| Subject:  | Re: 601xl aeilerons | 
      
      
      Hi Gig,
      
      I'm confused by your post.
      
      In the first part you say balancing control surfaces is done to 
      relieve control pressures.  In the second part you quote Bingelis 
      saying you only need to do this to reduce tendency for flutter.
      
      In the aileron case, when you move the stick one aileron goes up and 
      the other goes down.  This naturally provides balance from the 
      control stick's point of view.  It is true no matter how big the 
      plane is.  Said another way, the opposite aileron acts as a counter 
      balance.  This addresses the control balance issue without 
      considering the flutter issue which, I believe, is more of a single 
      control surface issue and requires the local counterbalance you see 
      on many higher performance planes.
      
      This is different from the elevator case where there is only one 
      moving control surface.  The bigger the elevator the more effort it 
      takes, on the ground, to raise it.  In the air, I submit it is the 
      airflow over the elevator and how much this is disrupted by a stick 
      movement that determines how much force is applied to the pitch axis 
      of the plane and how much feedback is applied to the stick.  The 
      large forward movement of the plane along with the elevator trim 
      keeps the elevator centered before moving the stick.  Still, a 
      counterbalance might be installed to reduce flutter tendencies in the 
      elevator in some designs.
      
      Paul
      XL getting close
      do not archive
      
      
      At 09:31 AM 10/23/2008, you wrote:
      
      >[quote="ideaz1(at)sbcglobal.net]Sorry to sound argumentative, but 
      >the balancing of control surfaces is to
      >releive the control forces required. Just picture a much larger aircraft
      >with the same setup as the XL and you would have a hard time controling the
      >plane at all; ...[/quote]
      >
      >
      >http://members.eaa.org/home/homebuilders/building/controls/Control%20Surface%20Balancing%20in%20Homebuilts.html?
      >
      >Control Surface Balancing in Homebuilts
      >Sport Aviation - 12/96
      >By Tony Bingelis
      >
      >The obvious question comes to mind. Why balance control surfaces? Do 
      >they really need to be balanced?
      >
      >Well, much seems to depend on the original design and construction 
      >of the control surfaces. Well-designed, rigid structures with little 
      >or no play in the hinges, control linkages, and trim tabs are less 
      >likely to be susceptible to flutter, hence, may not need to be 
      >statically balanced.
      >
      >--------
      >W.R. "Gig" Giacona
      >601XL Under Construction
      
      
Message 11
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  | 
      
      
| Subject:  | Re: 601xl aeilerons | 
      
      I have made demo flights in three different 601XL aircraft, two Continental powered
      and one Corvair. My previous experience is mostly C-152's, but also a few
      hours in the Tomahawk, Diamond Katana and Sonex. My impression of the 601XL is
      yes, roll control feels a little heavy, but I do not see this as a problem.
      It took only a few minutes to become familiar with it.
      
      Even large certified transports, such as fly-by-wire Airbus', do not necessarily
      have equal or even linear control forces in all axes.
      
      Jim LoBue
      601XL/Corvair
      
      --- On Thu, 10/23/08, Paul Mulwitz <psm@att.net> wrote:
      From: Paul Mulwitz <psm@att.net>
      Subject: Re: Zenith601-List: 601xl aeilerons
      
      
      Hi Brian,
      
      Thank you for your comment.  I think your point of view is very 
      valuable.  These issues are related but only distant relatives.
      
      This thread started as a discussion of heavy aileron forces on a demo 
      flight.  The counterbalances were added as a possible solution for 
      the heavy controls.  My last comment was to try to separate the 
      counterbalances from the heavy controls, but your take on this issue 
      seems like it is more clear.
      
      I want to try again to distinguish the heavy control issues without 
      regard to flutter.
      
      If you move the stick left and right on the ground, it takes a 
      significant amount of force to go from one limit to the other.  I 
      submit this is a minor issue.
      
      In the air, when you apply a side force to the stick the plane rolls 
      very nicely.  However, the stick doesn't move much at all in this 
      case.  For a pilot who gets his control feedback from the plane's 
      roll attitude this is not an issue.  For a different pilot who 
      ignores the plane's attitude and only considers how far the control 
      stick moves this is a problem.  I submit that a pilot should gauge 
      his actions by the response of the plane's attitude rather than the 
      movement of the stick.
      
      Best regards,
      
      Paul
      XL getting close
      do not archive
      
      At 09:17 AM 10/23/2008, you wrote:
      >>>I think you are discussing two different problems rather than one.
      >>
      >>                   No, not really... Heavy ailerons. Maybe there are 2
      >>solutions (or many more).
      >
      >Maybe we are discussing one issue, but we are offering solutions that are
      >designed to address two issues that are quite distinct,  control forces
      >and flutter. There are multiple ways to relieve the control forces,
      >including aerodynamic balance, balance tabs, spring tabs, weights, and
      >some others I can't remember at the moment.
      >
      >Flutter is a complex phenonemon that is dependant on balance, speed,
      >elasticity, airflow, and probably a host of others that I don't know
      about
      >(I am no engineer). It is often overcome by use of balance weights, as
      >well as careful engineering.
      >
      >Brian in Brazil
      
      
Message 12
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  | 
      
      
| Subject:  | Re: 601xl aeilerons | 
      
      
       To add to what Gig and Tony Benglis say, I think that nearly all "add-ons" (such
      as balance weights, VGs, etc.) are to overcome a not quite perfected design.?
      Granted, airplane design is really part science, part art. There is ample evidence
      that not all aeronautical engineers are skillful at blending all the requirements
      into a fully complete design that requires no "add-ons". Chris Heintz
      has been designing airplanes for a LONG time. I fully trust him and believe
      that if he thought aileron balance weights or VGs were necessary, they would
      have been there. 
      
      
      Jay in Dallas
      
      
      -----Original Message-----
      From: Gig Giacona <wrgiacona@gmail.com>
      Sent: Thu, 23 Oct 2008 11:31 am
      Subject: Zenith601-List: Re: 601xl aeilerons
      
      
      
      [quote="ideaz1(at)sbcglobal.net]Sorry to sound argumentative, but the balancing
      
      of control surfaces is to 
      releive the control forces required. Just picture a much larger aircraft 
      with the same setup as the XL and you would have a hard time controling the 
      plane at all; ...[/quote]
      
      
      http://members.eaa.org/home/homebuilders/building/controls/Control%20Surface%20Balancing%20in%20Homebuilts.html?
      
      Control Surface Balancing in Homebuilts
      Sport Aviation - 12/96
      By Tony Bingelis
      
      The obvious question comes to mind. Why balance control surfaces? Do they really
      
      need to be balanced?
      
      Well, much seems to depend on the original design and construction of the 
      control surfaces. Well-designed, rigid structures with little or no play in the
      
      hinges, control linkages, and trim tabs are less likely to be susceptible to 
      flutter, hence, may not need to be statically balanced.
      
      --------
      W.R. "Gig" Giacona
      601XL Under Construction
      See my progress at www.peoamerica.net/N601WR
      
      
      ________________________________________________________________________
      Email message sent from CompuServe - visit us today at http://www.cs.com
      
Message 13
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| Subject:  | Re: 601xl aeilerons | 
      
      
      Just a thought..
      You could not break the aeroplane with the way the ailerons are by design, 
      at any speed, but you could very easily break it with the sensitive 
      elevators at higher speeds.  However, you don't need to have more sensitive 
      ailerons for control at any speed, but you certainly need sensitive 
      elevators at low speed.
      I think that's why Chris designed it the way it is.
      Solution is, install roll trim.  I have and have flown many long flights 
      without any tiring effect.
      Dave Austin  601HDS - 912 
      
      
Message 14
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      Fellow builders,
      
      I am trying to get a little ahead on the wings and have my dad build the 
      ribs for my 601xl.  However, I have been looking around and flanging 
      dies are hard to come by unless you want to make them out of wood (which 
      is completely doable).  I had a local machine shop quote me for all 4 
      and they want $2300+ for the set! After I got done laughing, I starting 
      thinking of alternatives.  There are about 10k+ ways to skin this cat, 
      but I figured I'd see if anyone had a set for loan?
      
      
      -- 
      Lee Steensland
      601XL/Corvair (7637L reserved) Kit/Scratch builder 0.1% complete!
      
      
Message 15
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  | 
      
      
| Subject:  | Re: Flanging Dies | 
      
      
      Hi Lee,
      
      A slotted stick works really well for bending the flanges on 
      lightening holes.  I made one out of very fancy Russian 1/2" Russian 
      plywood.  I don't know my actual cost but it was probably something 
      around a nickel.
      
      Flanging dies are very nice if you are running a kit building factory 
      and don't really care how close the results are to the finished 
      needs.  After bending the flanges with a die you still need to use 
      the slotted stick to adjust the final bend to get a truly flat rib 
      web.  In the kit case this final step is left to the final kit builder.
      
      The problem is there is spring-back of the metal after being stamped 
      with the flanging dies.  This causes the rib web to spring back as 
      well and you get warped webs around the hole.  This is easy to 
      relieve with the slotted stick by bending the flange a little further 
      than the position it comes out of the die.  You just work your way 
      around the hole bending a little bit while watching the flatness of 
      the web against your work bench.  You will probably want to perform a 
      similar bending operation on the outside flange of each rib for the 
      same reasons.
      
      For scratch builders, you can do the same operation after cutting the 
      hole with the slotted stick and just skip the flanging die 
      altogether.  This will take an extra minute or so for each lightening hole.
      
      Good luck,
      
      Paul
      XL getting close
      
      
      At 05:06 PM 10/23/2008, you wrote:
      >Fellow builders,
      >
      >I am trying to get a little ahead on the wings and have my dad build 
      >the ribs for my 601xl.  However, I have been looking around and 
      >flanging dies are hard to come by unless you want to make them out 
      >of wood (which is completely doable).  I had a local machine shop 
      >quote me for all 4 and they want $2300+ for the set! After I got 
      >done laughing, I starting thinking of alternatives.  There are about 
      >10k+ ways to skin this cat, but I figured I'd see if anyone had a set for loan?
      >
      >
      >--
      >Lee Steensland
      >601XL/Corvair (7637L reserved) Kit/Scratch builder 0.1% complete!
      
      
Message 16
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  | 
      
      
| Subject:  | Re: Flanging Dies | 
      
      
      Lee-
          I believe Gary Boothe posted instructions on how to make them out of 
      wood that should be in the archives.
                                                          Bill
      ----- Original Message ----- 
      From: "Lee Steensland" <zenith-list@steensland.net>
      Sent: Thursday, October 23, 2008 8:06 PM
      Subject: Zenith601-List: Flanging Dies
      
      
      > <zenith-list@steensland.net>
      >
      > Fellow builders,
      >
      > I am trying to get a little ahead on the wings and have my dad build the 
      > ribs for my 601xl.  However, I have been looking around and flanging dies 
      > are hard to come by unless you want to make them out of wood (which is 
      > completely doable).  I had a local machine shop quote me for all 4 and 
      > they want $2300+ for the set! After I got done laughing, I starting 
      > thinking of alternatives.  There are about 10k+ ways to skin this cat, but 
      > I figured I'd see if anyone had a set for loan?
      >
      >
      > -- 
      > Lee Steensland
      > 601XL/Corvair (7637L reserved) Kit/Scratch builder 0.1% complete!
      >
      >
      > 
      
      
Message 17
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  | 
      
      
| Subject:  | Re: Flanging Dies | 
      
      Recently (a few weeks ago?) someone had a set available for loan.
      I don't remember on which of the Z lists, you would have to search the
      archives...
      
      Good luck
      
      Carlos
      CH601-HD, plans
      
      2008/10/23 Lee Steensland <zenith-list@steensland.net>
      
      > zenith-list@steensland.net>
      >
      > Fellow builders,
      >
      > I am trying to get a little ahead on the wings and have my dad build the
      > ribs for my 601xl.  However, I have been looking around and flanging dies
      > are hard to come by unless you want to make them out of wood (which is
      > completely doable).  I had a local machine shop quote me for all 4 and they
      > want $2300+ for the set! After I got done laughing, I starting thinking of
      > alternatives.  There are about 10k+ ways to skin this cat, but I figured I'd
      > see if anyone had a set for loan?
      >
      >
      > --
      > Lee Steensland
      
Message 18
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  | 
      
      
| Subject:  | Re: Flanging Dies | 
      
      Do not archive
      
      Are there now four flanging die sizes needed for the 601?  There used to 
      be three; 65, 95, 115.  What's new?
      
      Regards,
      
      Randy, Las Vegas
      
      
         I had a local machine shop quote me for all 4 and they want $2300+
      
Message 19
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  | 
      
      
| Subject:  | Re: Flanging Dies | 
      
      
      Hey Lee,
      
      Just for another perspective, I'll throw in my two cents. Making the dies out of
      locally available oak (like at Home Depot) is really not too hard, although
      it does require a lathe. I bet you could get a high school shop class to turn
      yours for less than $2300. (LOL - I was floored by that - sounds like you were
      too.) If you check my Kitlog site, there are some pretty good pictures that detail
      how I glued mine up and turned them. I'm including the link below. 
      
      I must not have been doing something right with the "slotted stick" method. I've
      read plenty of guys who had luck with it, but mine always ended up looking like
      hell. BTW, my dies are in use or you could use them - still can if you want
      to wait a little while.
      
      I have noticed that some people mention an "oil-canning" or bowing of the webs
      that I never experienced. I've come to suspect that most people who got that result
      did one of two things...
      
      1.) Either their dies never included, or had an ill-formed "shelf" portion at the
      top of the die - the part that actually straightens the web back out to 90-degrees
      after flanging the hole. I've seen people make the beveled part of the
      die with a router bit and never include the flat "shelf." An early experiment
      of mine didn't have the flat part, and they bowed the webs like crazy. The little
      flat part at the top is very important.
      
      2.) Their dies included the flat shelf, but they never hauled-off and whacked the
      die as hard as you need to to straighten it out properly.
      
      I've said it before, I'm no expert - just offering another opinion. Good luck,
      and I hope this helps!
      
      Debo Cox
      Nags Head, NC
      Scratchbuilt XL/Corvair
      Airframe 85% complete
      www.mykitlog.com/debo
      
      
Message 20
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| Subject:  | Re: Flanging Dies | 
      
      
      There are plans for dies on the ch601.org web site. I was fortunate enough to have
      Debo's dies. 
      
      Dave Clay
      Temple, TX
      
      
      Read this topic online here:
      
      http://forums.matronics.com/viewtopic.php?p=210069#210069
      
      
 
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