---------------------------------------------------------- Zenith601-List Digest Archive --- Total Messages Posted Fri 06/18/10: 6 ---------------------------------------------------------- Today's Message Index: ---------------------- 1. 07:12 AM - Aileron balance install (Tim Juhl) 2. 07:33 AM - Re: Aileron balance install (Paul Mulwitz) 3. 12:55 PM - Rivet Removal (Stephen R. Look) 4. 01:03 PM - Re: Aileron balance install (Mark Hubelbank) 5. 04:59 PM - Re: Aileron balance install (Afterfxllc@aol.com) 6. 08:36 PM - Re: Aileron balance install (Ron Lendon) ________________________________ Message 1 _____________________________________ Time: 07:12:02 AM PST US Subject: Zenith601-List: Aileron balance install From: "Tim Juhl" I'm getting ready to install the aileron balance in my right aileron. Looking at the LAA drawings provided by Zenith for the upgrade I see that they set the ribs that support the square tube used as a balance arm parallel to the other ribs in the aileron. This would result in the tube not being at a right angle to the rear spar. In my view, this would result in requiring a wider hole in the spar to accommodate the lateral movement of the tube when the aileron is deflected. I also believe there was an earlier discussion of the need to bend the tube inwards to clear the wingtip rivet line. I wonder how others have dealt with this issue. I'm consideringL 1.) installing the ribs supporting the tube so as to place the tube at a right angle to the spar, & 2.) Moving the tube inwards slightly to assure clearance from structures in the wing. I'd appreciate your comments before I start cutting :) Tim Juhl -------- ______________ CFII Champ L16A flying Zodiac XL - Jabiru 3300A Tearing wings apart for modification Read this topic online here: http://forums.matronics.com/viewtopic.php?p=301668#301668 ________________________________ Message 2 _____________________________________ Time: 07:33:57 AM PST US From: "Paul Mulwitz" Subject: RE: Zenith601-List: Aileron balance install Hi Tim, On mine, I installed the balance rod perpendicular to the MAIN spar. That means an angle (not perpendicular) to the rear spar and aileron hinge. I don't know what all the issues are for this problem. One seems to be how the weights move between the rear rib and wing tip as well as the two wing skins. Good luck, Paul XL - slowly installing upgrade - currently fighting removing large spar rivets. -----Original Message----- From: owner-zenith601-list-server@matronics.com [mailto:owner-zenith601-list-server@matronics.com] On Behalf Of Tim Juhl Sent: Friday, June 18, 2010 7:12 AM Subject: Zenith601-List: Aileron balance install I'm getting ready to install the aileron balance in my right aileron. Looking at the LAA drawings provided by Zenith for the upgrade I see that they set the ribs that support the square tube used as a balance arm parallel to the other ribs in the aileron. This would result in the tube not being at a right angle to the rear spar. In my view, this would result in requiring a wider hole in the spar to accommodate the lateral movement of the tube when the aileron is deflected. I also believe there was an earlier discussion of the need to bend the tube inwards to clear the wingtip rivet line. I wonder how others have dealt with this issue. I'm consideringL 1.) installing the ribs supporting the tube so as to place the tube at a right angle to the spar, & 2.) Moving the tube inwards slightly to assure clearance from structures in the wing. I'd appreciate your comments before I start cutting :) Tim Juhl -------- ______________ CFII Champ L16A flying Zodiac XL - Jabiru 3300A Tearing wings apart for modification Read this topic online here: http://forums.matronics.com/viewtopic.php?p=301668#301668 ________________________________ Message 3 _____________________________________ Time: 12:55:00 PM PST US From: "Stephen R. Look" Subject: Zenith601-List: Rivet Removal My two cents on removing solid spar rivets: I'm drilling the heads with a #20 drill down to about even with the sheet metal and then using a Stanley wood chisel to remove the head. Three or four hits with my little hammer and the head goes flying. Barely even scuffs the surface of the sheet metal. When I'm all done the chisel won't be worth much, but it was pretty cheap. Getting the rest of the rivet out I use a small pin punch and whack it a few times. Steve Steve Look Monticello, IL www.ilrt66.com "Dogs have owners, Cats have staff" ________________________________ Message 4 _____________________________________ Time: 01:03:58 PM PST US From: Mark Hubelbank Subject: Re: Zenith601-List: Aileron balance install Tim, I did two things. First I did not keep the arms parallel to the ribs. I shifted them just enough so they would be far enough away from the other structures so no interference was possible (including the metal plates). I allowed about 1 inch from the end of the tube to any other part. Secondly, I filled about 7 inches of the end of the square tube with lead. It melts at about 600-700F and alumimum is melts at around 1200F so as long as one keeps the lead at just above the melting point it works. I stuffed and tamped aluminim foil into the tube to act as a plug to define the area to be filled. A heat gun was used to pre-heat the tube a bit so the lead would flow all the way to the plug. The lead was melted using a 1500W hot plate with the lead in a metal coffee can and with a larger metal can inverted over that to keep the heat in. It took about 40 minutes to get the lead all melted. You will need about 1.5 pounds of lead for each side. I started with 5 pounds total and that made it easy to pour. Doing this I only needed two steel plates to balance. This allowed one to use the specified holes by turning the aileron vertical to insert the tube in the hole with the balance plates on. This way the aileron can be removed in the future. On 06/18/2010 10:11 AM, Tim Juhl wrote: > --> Zenith601-List message posted by: "Tim Juhl" > > I'm getting ready to install the aileron balance in my right aileron. Looking at the LAA drawings provided by Zenith for the upgrade I see that they set the ribs that support the square tube used as a balance arm parallel to the other ribs in the aileron. This would result in the tube not being at a right angle to the rear spar. In my view, this would result in requiring a wider hole in the spar to accommodate the lateral movement of the tube when the aileron is deflected. I also believe there was an earlier discussion of the need to bend the tube inwards to clear the wingtip rivet line. > I wonder how others have dealt with this issue. I'm consideringL > 1.) installing the ribs supporting the tube so as to place the tube at a right angle to the spar,& > 2.) Moving the tube inwards slightly to assure clearance from structures in the wing. > > I'd appreciate your comments before I start cutting :) > > Tim Juhl > > -------- > ______________ > CFII > Champ L16A flying > Zodiac XL - Jabiru 3300A > Tearing wings apart for modification > > > Read this topic online here: > > http://forums.matronics.com/viewtopic.php?p=301668#301668 > > > -- Mark Hubelbank NorthEast Monitoring 2 Clock Tower Place Suite 555 Maynard, MA, 01754 - USA mhubel@nemon.com 978-443-3955 ________________________________ Message 5 _____________________________________ Time: 04:59:53 PM PST US From: Afterfxllc@aol.com Subject: Re: Zenith601-List: Aileron balance install I moved the balance arm 100 mm inboard and it clears with no bending of the arm. If you install the ribs at the same angle as the other ribs it is a bit more difficult to align everything but I feel looks better. Jeff In a message dated 6/18/2010 10:12:44 A.M. Eastern Daylight Time, juhl@avci.net writes: --> Zenith 601-List message posted by: "Tim Juhl" I'm getting ready to install the aileron balance in my right aileron. Looking at the LAA drawings provided by Zenith for the upgrade I see that they set the ribs that support the square tube used as a balance arm parallel to the other ribs in the aileron. This would result in the tube not being at a right angle to the rear spar. In my view, this would result in requiring a wider hole in the spar to accommodate the lateral movement of the tube when the aileron is deflected. I also believe there was an earlier discussion of the need to bend the tube inwards to clear the wingtip rivet line. I wonder how others have dealt with this issue. I'm consideringL 1.) installing the ribs supporting the tube so as to place the tube at a right angle to the spar, & 2.) Moving the tube inwards slightly to assure clearance from structures in the wing. I'd appreciate your comments before I start cutting :) Tim Juhl -------- ______________ CFII Champ L16A flying Zodiac XL - Jabiru 3300A Tearing wings apart for modification Read this topic online here: http://forums.matronics.com/viewtopic.php?p=301668#301668 ________________________________ Message 6 _____________________________________ Time: 08:36:54 PM PST US Subject: Zenith601-List: Re: Aileron balance install From: "Ron Lendon" The one I just did I just made square to the hinge line and picked up two existing rivets for the new rib rivet lines. I checked clearance with a large carpenters square from the center of one rivet and wouldn't ya know, the next rivet was 40mm away, ( just perfect for the rib lines) . It was very easy to draw those lines around the aileron skin using a square. Once the lines were drawn just mark and drill the end holes, and rivet fan for the 5 rivets on the end, and 8 rivets top and bottom. -------- Ron Lendon, Clinton Township, MI WW Corvair with Roy's Garage 5th bearing Zodiac XL, ScrapBuilder ;-) http://www.mykitlog.com/rlendon Read this topic online here: http://forums.matronics.com/viewtopic.php?p=301722#301722 Attachments: http://forums.matronics.com//files/zu_108a_210.jpg http://forums.matronics.com//files/zu_104_442.jpg ------------------------------------------------------------------------------------- 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.