---------------------------------------------------------- Zenith601-List Digest Archive --- Total Messages Posted Thu 01/21/10: 9 ---------------------------------------------------------- Today's Message Index: ---------------------- 1. 05:52 AM - Re: Upgrade kit (DaveG601XL) 2. 07:05 AM - Upgrade Kit Rivet Removal (Bill Pagan) 3. 07:40 AM - Re: Upgrade Kit Rivet Removal (clmelenyzeriv@cs.com) 4. 08:18 AM - Re: Upgrade Kit Rivet Removal (DaveG601XL) 5. 01:24 PM - Re: Upgrade Kit Rivet Removal (mhubel) 6. 01:32 PM - Re: 601XL gear removal for seat modifications (mhubel) 7. 02:38 PM - Re: Upgrade kit (Sabrina) 8. 07:47 PM - Re: Upgrade kit (chris Sinfield) 9. 08:44 PM - Re: Upgrade Kit Rivet Removal (Ron Lendon) ________________________________ Message 1 _____________________________________ Time: 05:52:17 AM PST US Subject: Zenith601-List: Re: Upgrade kit From: "DaveG601XL" The externally braced idea with an open cockpit gives me visions of a 2-place Bowers Fly Baby. -------- David Gallagher 601 XL/Jabiru 3300 First flight 7/24/08 116.5 hours and holding (incorporating upgrade) Read this topic online here: http://forums.matronics.com/viewtopic.php?p=282693#282693 ________________________________ Message 2 _____________________________________ Time: 07:05:18 AM PST US From: Bill Pagan Subject: Zenith601-List: Upgrade Kit Rivet Removal Hey all,=0A-=0ANeed some advice on rivet removal.- On the spar solid ri vets, I've drilled the heads of the rivets and used a chisel to pop the hea ds off (just like in the videos).- I center drilled a relief hole 3/4 or so through the rivet and-the 9 rivets outboard of rib #6 came out pretty easily when I used my 3x rivet gun to drive them out.- However, the rivet s inboard of rib #6 where the spar cap-doubles up I can't get the rivets to budge.- I'm using a-3x rivet-gun at about 100psi. I actually bent the punch I'm using in the rivet gun.- Any advice is greatly appreciated. - I'm really good at busting stuff and want to be especially careful here .=0A=0A-Bill Pagan-=0A=0A=0A ________________________________ Message 3 _____________________________________ Time: 07:40:02 AM PST US Subject: Re: Zenith601-List: Upgrade Kit Rivet Removal From: clmelenyzeriv@cs.com Bill, I have not started taking my wings apart yet, but I did my center spar. An EAA friend suggested using a roller chain breaker. I bought one at Ha rbor Freight for $10 tax included. I started just as you did by drilling off the factory head and flushing the rivet stem to the flat bar stock. I then removed the bottom receiver from the chain breaker, put the chain breaker over the bar with the drive pin centered on the factory head side , and turned the pin driver with a ratchet wrench easily pushing the rivet through the chain breaker's receiving end. In anticipating working on the wing spars I ground out about 2 millimeters of the chain breaker throat because it needs to be deeper to span the 2 flat bars and web. I anticipate that I will have to trim the flange off of the angle and work from the fuselage end to the tip. It worked well without hammering. Just be careful to center the drive pin on the rivet. I have ground the pin diameter down a little so that cente ring does not have to be exact. I can be reached at 423-667-3635 if I have not explained this clearly. C. L. Melenyzer IV 601XL wings completed and working on 650XL fuselage while waiting on upgr ade kit. -----Original Message----- From: Bill Pagan Sent: Thu, Jan 21, 2010 10:03 am Subject: Zenith601-List: Upgrade Kit Rivet Removal Hey all, Need some advice on rivet removal. On the spar solid rivets, I've drilled the heads of the rivets and used a chisel to pop the heads off (just like in the videos). I center drilled a relief hole 3/4 or so through the riv et and the 9 rivets outboard of rib #6 came out pretty easily when I used my 3x rivet gun to drive them out. However, the rivets inboard of rib #6 where the spar cap doubles up I can't get the rivets to budge. I'm using a 3x rivet gun at about 100psi. I actually bent the punch I'm using in th e rivet gun. Any advice is greatly appreciated. I'm really good at busti ng stuff and want to be especially careful here. Bill Pagan ________________________________ Message 4 _____________________________________ Time: 08:18:43 AM PST US Subject: Zenith601-List: Re: Upgrade Kit Rivet Removal From: "DaveG601XL" Bill, Make sure you clamp tightly on each side of the rivet you are trying to remove. The multiple layers of aluminum, if allowed to separate, will grip the rivet firmly. -------- David Gallagher 601 XL/Jabiru 3300 First flight 7/24/08 116.5 hours and holding (incorporating upgrade) Read this topic online here: http://forums.matronics.com/viewtopic.php?p=282726#282726 ________________________________ Message 5 _____________________________________ Time: 01:24:51 PM PST US Subject: Zenith601-List: Re: Upgrade Kit Rivet Removal From: "mhubel" The chain breaker may work but one needs to relief the pressure of the rivet. I drilled the -6 rivets out with a #20 (1/8 inch) drill almost all the way through. I found that one has to at least have the drill tip go up to the "shop head". I then used a 1/8 punch with a 2X air hammer set at a low pressure. The few times the shop head came off, I was able to drive the whole remaining rivet body out with a 3/16 punch. Keeping all the pieces tight while doing this also helps and reduces the strain on any one piece of metal. -------- Mark Hubelbank N708HU CH601XL Jabiru 3300 Rotec TBI 40 carb Sensenich ground adj prop. 41 hr TAF Pictures at photo.hubbles.com Read this topic online here: http://forums.matronics.com/viewtopic.php?p=282782#282782 ________________________________ Message 6 _____________________________________ Time: 01:32:21 PM PST US Subject: Zenith601-List: Re: 601XL gear removal for seat modifications From: "mhubel" For what it is worth, we decided to remove the gear. I still had all the supports that were used while the fuselage was being supported without the gear during construction so it was less than an hour to take the gear off. Then perhaps another hour to get all the additional rivets out that were in the way. While this may be a break even in time, I think it will lead to a nicer job. I also intend to put the center console back in in a manner that partial removal is possible. I have never worked on a plane before where there was no nice way to properly fasten wires that went through to the aft area. I think this will be much more professional. -------- Mark Hubelbank N708HU CH601XL Jabiru 3300 Rotec TBI 40 carb Sensenich ground adj prop. 41 hr TAF Pictures at photo.hubbles.com Read this topic online here: http://forums.matronics.com/viewtopic.php?p=282783#282783 ________________________________ Message 7 _____________________________________ Time: 02:38:31 PM PST US Subject: Zenith601-List: Re: Upgrade kit From: "Sabrina" maybe I could test my flying motorcycle wing design by turning my fly baby into a Bowers Bi-baby... just kidding, but you are on point... with strain gauges being so small and accurate, it would not be too hard to have the Dynon display and record the forces on the external bracing... the open cockpit would only be for the first few hours of new phase 1 testing... Read this topic online here: http://forums.matronics.com/viewtopic.php?p=282789#282789 ________________________________ Message 8 _____________________________________ Time: 07:47:46 PM PST US Subject: Zenith601-List: Re: Upgrade kit From: "chris Sinfield" Sabrina back on the main Zenith site there are pictures of 601's without canopies and just a small windshield. they also have the back luggage area blocked off so the wind does not get in and peal it open. So it has been done and it does fly.. Chris Read this topic online here: http://forums.matronics.com/viewtopic.php?p=282837#282837 ________________________________ Message 9 _____________________________________ Time: 08:44:35 PM PST US Subject: Zenith601-List: Re: Upgrade Kit Rivet Removal From: "Ron Lendon" bill.pagan(at)yahoo.com wrote: > [img]cid:1264086095309@dclient.mail.yahoo.com[/img] > Hey all, > > Need some advice on rivet removal. On the spar solid rivets, I've drilled the heads of the rivets and used a chisel to pop the heads off (just like in the videos). I center drilled a relief hole 3/4 or so through the rivet and the 9 rivets outboard of rib #6 came out pretty easily when I used my 3x rivet gun to drive them out. However, the rivets inboard of rib #6 where the spar cap doubles up I can't get the rivets to budge. I'm using a 3x rivet gun at about 100psi. I actually bent the punch I'm using in the rivet gun. Any advice is greatly appreciated. I'm really good at busting stuff and want to be especially careful here. > > > > Bill Pagan Bill, What worked best for me was the Navy method. Center punch factory head, Pilot drill 3/32 and keep it centered, #30 drill using tool to hold drill perpendicular and control depth, Chisel off the head, use 1/8 pin punch and have helper hold bucking bar flat next to the shop head and using hammer tap it out. The top picture at this link shows the tool and depth used. http://mykitlog.com/users/display_log.php?user=rlendon&project=780&category=0&log=94961&row=14 Here is a link that gave me some ideas: http://wiki.matronics.com/wiki/index.php/Removing_Solid_Rivets Hope that helps, -------- Ron Lendon, Clinton Township, MI WW Corvair with Roy's Garage 5th bearing Zodiac XL, ScrapBuilder ;-) http://www.mykitlog.com/rlendon Corvair Engine Prints: http://home.comcast.net/~rlendon/site/ Read this topic online here: http://forums.matronics.com/viewtopic.php?p=282841#282841 ------------------------------------------------------------------------------------- Other Matronics Email List Services ------------------------------------------------------------------------------------- Post A New Message zenith601-list@matronics.com UN/SUBSCRIBE http://www.matronics.com/subscription List FAQ http://www.matronics.com/FAQ/Zenith601-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/zenith601-list Browse Digests http://www.matronics.com/digest/zenith601-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.