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Matt Ronics
Joined: 30 Apr 2007 Posts: 22
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Posted: Wed Dec 19, 2007 10:48 pm Post subject: Re: 601 and wing failiers |
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I'll flog the dead horse with my take. I chose to build a 701 instead of 601XL over this issue. I considered a 601HD but found that the 701 was close enough to 601HD speeds to suit my needs. I've previously built a canard composite.
The issue I have with the 601XL failures is simply that they are not adequately defined. My talk with Sebastian didn't help this concern.
My totally unsubstantiated theory is that the design, as it currently exists, is intolerant of some combination of builder error. A failure to design in enough "builder error tolerances" may explain why most 601XLs will fly forever (and test well with sandbags) and a few will catastrophically fail. Who knows if you might make just the right combination of fatal flaws when building your 601XL.
Even in the event of pilot error, when reviewing other fleet aircraft, wings just don't seem to come off as often as with the 601XL. I am not arguing that the Rutan canard is a superior aircraft, but there has simply not been an airframe failure in the canard fleet, even though 2000+ airframes have been built by amateur builders. So long as builders have *attempted* to place all the layers of fiberglass on, and balanced the surfaces, none have failed the structure in flight (even well past VNE). There is a tremendous amount of "margins for error" designed into the Rutan canard. I don't think such a margin exists in the 601XL spar/wing design.
My opinions only.
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Martin Pohl

Joined: 30 Jan 2006 Posts: 118 Location: CH-8645 Jona SG, Switzerland
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jetboy
Joined: 22 Jul 2006 Posts: 233
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Posted: Thu Dec 20, 2007 1:29 am Post subject: Re: 601 and wing failiers |
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I'm concerned about the XL wing as to whether it may be susceptible to flutter, induced by improper handling or loading. At least one pilot report of "washboarding" on this list remains unexplained. Its only the XL wing that seems to be affected, although I would be confident to fly in one that was built standard, and flown appropriately, but would be reassured if some flight test data was tabled showing how the prototypes handled these conditions - by what margin they were tested to - and whether the CZAW mods were ever put thru the same testing? Not advocating for any retest of this - just confirmation of what tolerance for loading / CG and Vne / Vd exists?
When choosing the 701, I could have fitted an 0-200 as I already had one in a C150 that I was parting with, but chose to not use it because of the extra vibration - especially if running rough or 1 cyl. out, could be a bit much for the airframe, and besides, the weight puts it outside the design envelope. The fatal crash in Canada and the cracking of Horiz. stab attach brackets when used with the 912S are examples taken into account.
Ralph
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tjs22t(at)verizon.net Guest
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Posted: Thu Dec 20, 2007 2:34 am Post subject: 601 and wing failiers |
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Martin,
I respectfully disagree with your statement below and would like you to back
it up with some factual , empirical evidence. As Larry stated yesterday the
D-tube structure of the wing gives it the strength.
tj do not archive
Quote: |
Nevertheless it is true of course that the wing structure itself is
weakened by the lockers.
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psm(at)ATT.NET Guest
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Posted: Thu Dec 20, 2007 3:12 am Post subject: 601 and wing failiers |
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I can't say you are wrong about the "Builder margin" issue, but I can
say I disagree with you (whoever you are). There is a basic
difference between conventional airplane design and canard
architecture that might explain this little mystery. Canards cannot
be allowed to stall, because if they do the result is always
unrecoverable and fatal.
If the main wing in a canard airplane stalls before the front wing,
the plane will fall tail first through the air. That is a certain
death for the plane and all the folks in it. To prevent this
catastrophic flight condition, canard designers must limit the
elevator authority so that stalls of the main wing are impossible.
The Zodiac XL is designed with extremely effective control surfaces
in all three axes. That means the pilot has great control of the
plane even at very low airspeeds. The down side of this choice is
the pilot can assert such great forces on the airframe when the plane
is going fast and he applies high control force inputs that he can
literally pull the wings off. Chris Heintz seems to always refer to
this design choice when he writes about the structural failure
issue. It is a potential problem for pilots who are prone to panic
or otherwise tend to use ridiculously high forces on the controls.
We will never know exactly why there are alarmingly high failures on
Zodiac XLs. They might just go away, or some day there might be a
little "Beef up" fix like there was on the V-Tail Bonanzas after
decades of in-flight structural failures. Still, most of the XL
drivers and builders must be doing something right because the number
of failures still represents only a very small percentage of the flying XLs.
Paul
XL fuselage
At 10:48 PM 12/19/2007, you wrote:
Quote: |
I'll flog the dead horse with my take. I chose to build a 701
instead of 601XL over this issue. I considered a 601HD but found
that the 701 was close enough to 601HD speeds to suit my
needs. I've previously built a canard composite.
The issue I have with the 601XL failures is simply that they are not
adequately defined. My talk with Sebastian didn't help this concern.
My totally unsubstantiated theory is that the design, as it
currently exists, is intolerant of some combination of builder
error. A failure to design in enough "builder error tolerances" may
explain why most 601XLs will fly forever (and test well with
sandbags) and a few will catastrophically fail. Who knows if you
might make just the right combination of fatal flaws when building your 601XL.
Even in the event of pilot error, when reviewing other fleet
aircraft, wings just don't seem to come off as often as with the
601XL. I am not arguing that the Rutan canard is a superior
aircraft, but there has simply not been an airframe failure in the
canard fleet, even though 2000+ airframes have been built by
amateur builders. So long as builders have *attempted* to place all
the layers of fiberglass on, and balanced the surfaces, none have
failed the structure in flight (even well past VNE). There is a
tremendous amount of "margins for error" designed into the Rutan
canard. I don't think such a margin exists in the 601XL spar/wing design.
My opinions only.
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planecrazydld(at)yahoo.co Guest
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Posted: Thu Dec 20, 2007 3:22 am Post subject: 601 and wing failiers |
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or with a little redesign, the inboard leading edge couild easily become genuine wet wing fuel storage - more fuel, less weight - just more Proseal 890!
ashontz <ashontz(at)nbme.org> wrote:[quote] --> Zenith-List message posted by: "ashontz"
I thought I saw the wing lockers in the HD in the center spar. My bad. Still, they're shorter wing panels.
Anyway, I'm done over analyzing the XL wing, but personally, I won't install the wing lockers. Something about it from a "seat of your pants" engineering style, it just looks "not right" to me. I also think making some other changes like the 15 gallon tanks which puts a nose rib out of alignment with a rear rib, especially in conjunction with a wing locker and a nose skin made of shorter skins is asking for trouble. Any one of them are their own isn't a problem (except Find them fast with Yahoo! Search. [quote][b]
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planecrazydld(at)yahoo.co Guest
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Posted: Thu Dec 20, 2007 3:33 am Post subject: 601 and wing failiers |
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why could the lockers simply be moved completly to the next to last bay outboard? That would span load the weight of their contents and reduce the effect on panel bending. Of course, then you have higher polar moments for things like spins or upset recovery...
Martin Pohl <mpohl(at)pohltec.ch> wrote:[quote] --> Zenith-List message posted by: "Martin Pohl"
Hello everybody!
I personally like the wing locker option: I'd rather have my 70 lbs baggage in the wings (wing lockers) and stress the wing spar at the wing/fuselage connection to a much lesser extent than when having all this stuff in my aft baggage compartment.
Nevertheless it is true of course that the wing structure itself is weakened by the lockers.
So lets go and start an effective diet and loose some pounds: that most probably is the best Find them fast with Yahoo! Search. [quote][b]
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Iberplanes
Joined: 10 Dec 2007 Posts: 174 Location: Igualada - Barcelona - Spain
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Posted: Thu Dec 20, 2007 4:55 am Post subject: 601 and wing failiers |
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Hi,
Is it possible not to install the wing lockers even if you have ordered
them? I´m waiting my crate to arrive in january, but I´m re-thinking due to
the comments I´m reading here on not to construct that part.
Please, tell me.
---
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_________________ Alberto Martin
601 XL - Jabiru 3300
http://www.iberplanes.es
Igualada - Barcelona - Spain |
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notsew_evets(at)frontiern Guest
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Posted: Thu Dec 20, 2007 5:07 am Post subject: 601 and wing failiers |
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Yes.
You are the builder and do the actually cutting and installation.
I m just now finishing the lockers and the addition of the rear panel is
beefy. Probably stronger than the plain ol skin.
How
ever, even with the extra "baggage" space, I kinda wish I would have waited
to hear the outcome of this thread before installing.....
Steve 601 XL QBK
---
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ashontz

Joined: 27 Dec 2006 Posts: 723
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Posted: Thu Dec 20, 2007 5:27 am Post subject: Re: 601 and wing failiers |
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Ok, this is a little more sane and less emotional thread on the issue, that's good. It's nothing more than load analysis. Analyze the loads compression and tension for the whole wing as well as what would be happening between each rib station to make it fold and you can identify the stress points. Thinking of it as a big piece of Origami helps too. "If I attempt to fold this, which way do the connecting pieces need to move and with how much force, and what's keeping those connecting pieces from moving, and what does it take to move the connecting pieces to the connecting pieces."
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bill_dom(at)yahoo.com Guest
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Posted: Thu Dec 20, 2007 6:03 am Post subject: 601 and wing failiers |
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I don't believe it has something to do with builder error, one of the failure cases was with a factory build AMD Zodiac. I don't believe this accident was due to an explosion as some people has mention, the report for this accident states "no evidence of fire was found" If there is a flaw in the design (I'm not sure there is one), I think it is one that only comes during very specific flight situation that provoke a failure when it shouldn't. Of course, this are just my beliefs based on info available and they can change as new info comes out.
William Dominguez
Zodiac 601XL Plans
Miami, Florida
Matt Ronics <e_jocular(at)yahoo.com> wrote:[quote] --> Zenith-List message posted by: "Matt Ronics"
I'll flog the dead horse with my take. I chose to build a 701 instead of 601XL over this issue. I considered a 601HD but found that the 701 was close enough to 601HD speeds to suit my needs. I've previously built a canard composite.
The issue I have with the 601XL failures is simply that they are not adequately defined. My talk with Sebastian didn't help this concern.
My totally unsubstantiated theory is that the design, as it currently exists, is intolerant of some combination of builder error. A failure to design in enough "builder error tolerances" may explain why most 601XLs will fly forever (and test well with sandbags) and a few will catastrophically fail. Who knows if you might make just the right combination of fatal flaws when building your 601XL.
Even in the event of pilot error, when reviewing other fleet aircraft, wings just don't seem to come off as often as with the 601XL. I am not arguing that the Rutan canard is a superior aircraft, but there has simply not been an airframe failure in the canard fleet, even though 2000+ airframes have [quote][b]
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ashontz

Joined: 27 Dec 2006 Posts: 723
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Posted: Thu Dec 20, 2007 6:40 am Post subject: Re: 601 and wing failiers |
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The more I read people's input, the more I'm considering adding ribs. Granted, Zenith themselves say that you can overstress the structure with quick hard control inputs, specifically elevator. I don't think adding a few ribs would hurt or even be a big problem. In fact, I'm sure I can use the existing holes in the main spar where the hat stiffeners are to add ribs without drilling more holes in the main spar. More ribs would add more torsional strength as well as shortening the bending moments in the wing itself between rib stations. Wouldn't even be that hard to interpolate the dimensions for the new interim ribs, mostly just time making about 4 more rib forms. That with no wing locker and I think you're looking at a significantly stronger wing to make up for any possible design flaw or builder error nor would it push stress somewhere else that that stress shouldn't be going anyway. If it adds more stress to the root, oh well, that's the roots job, to hold the damn wing on, and in the reports there was no mention of the bolts at the root shearing. And if you wanted to beef up the root that would be pretty easy too, just add some plate to span more of the center spar and add more bolts. But that doesn't seem to be an issue.
[quote="bill_dom(at)yahoo.com"]I don't believe it has something to do with builder error, one of the failure cases was with a factory build AMD Zodiac. I don't believe this accident was due to an explosion as some people has mention, the report for this accident states "no evidence of fire was found" If there is a flaw in the design (I'm not sure there is one), I think it is one that only comes during very specific flight situation that provoke a failure when it shouldn't. Of course, this are just my beliefs based on info available and they can change as new info comes out.
William Dominguez
Zodiac 601XL Plans
Miami, Florida
Matt Ronics <e_jocular> wrote:[quote] --> Zenith-List message posted by: "Matt Ronics"
I'll flog the dead horse with my take. I chose to build a 701 instead of 601XL over this issue. I considered a 601HD but found that the 701 was close enough to 601HD speeds to suit my needs. I've previously built a canard composite.
The issue I have with the 601XL failures is simply that they are not adequately defined. My talk with Sebastian didn't help this concern.
My totally unsubstantiated theory is that the design, as it currently exists, is intolerant of some combination of builder error. A failure to design in enough "builder error tolerances" may explain why most 601XLs will fly forever (and test well with sandbags) and a few will catastrophically fail. Who knows if you might make just the right combination of fatal flaws when building your 601XL.
Even in the event of pilot error, when reviewing other fleet aircraft, wings just don't seem to come off as often as with the 601XL. I am not arguing that the Rutan canard is a superior aircraft, but there has simply not been an airframe failure in the canard fleet, even though 2000+ airframes have
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bryanmmartin
Joined: 10 Jan 2006 Posts: 1018
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Posted: Thu Dec 20, 2007 7:33 am Post subject: 601 and wing failiers |
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Just because there was no evidence of a fire does not mean there
wasn't an explosion. It is entirely possible to have an explosion
without a fire and without leaving any signs of heat damage. An
explosion does most of its damage because of the extreme pressures
produced, not from the heat. Debris from the explosion is often not
exposed to the heat for long enough to be damaged by it. Explosions in
real life don't necessarily act like they do in the movies.
On Dec 20, 2007, at 8:56 AM, William Dominguez wrote:
Quote: | I don't believe it has something to do with builder error, one of
the failure cases was with a factory build AMD Zodiac. I don't
believe this accident was due to an explosion as some people has
mention, the report for this accident states "no evidence of fire
was found" If there is a flaw in the design (I'm not sure there is
one), I think it is one that only comes during very specific flight
situation that provoke a failure when it shouldn't. Of course, this
are just my beliefs based on info available and they can change as
new info comes out.
|
--
Bryan Martin
N61BM, CH 601 XL,
RAM Subaru, Stratus redrive.
do not archive.
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_________________ --
Bryan Martin
N61BM, CH 601 XL, Stratus Subaru.
do not archive. |
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ashontz

Joined: 27 Dec 2006 Posts: 723
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Posted: Thu Dec 20, 2007 7:58 am Post subject: Re: 601 and wing failiers |
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And if there was an explosion, it's more than likely that the tank leaked somehow and fumes accummulated in the wing structure. An explosion is more likely when there's less fuel to air ratio. An outright explosion of the tank is unlikely, a small amount of fuel in the wink with a lot of air would make a bigger boom.
bryanmmartin wrote: | Just because there was no evidence of a fire does not mean there
wasn't an explosion. It is entirely possible to have an explosion
without a fire and without leaving any signs of heat damage. An
explosion does most of its damage because of the extreme pressures
produced, not from the heat. Debris from the explosion is often not
exposed to the heat for long enough to be damaged by it. Explosions in
real life don't necessarily act like they do in the movies.
On Dec 20, 2007, at 8:56 AM, William Dominguez wrote:
Quote: | I don't believe it has something to do with builder error, one of
the failure cases was with a factory build AMD Zodiac. I don't
believe this accident was due to an explosion as some people has
mention, the report for this accident states "no evidence of fire
was found" If there is a flaw in the design (I'm not sure there is
one), I think it is one that only comes during very specific flight
situation that provoke a failure when it shouldn't. Of course, this
are just my beliefs based on info available and they can change as
new info comes out.
|
--
Bryan Martin
N61BM, CH 601 XL,
RAM Subaru, Stratus redrive.
do not archive. |
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paulrod36(at)msn.com Guest
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Posted: Thu Dec 20, 2007 9:34 am Post subject: 601 and wing failiers |
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<?xml:namespace prefix="v" /><?xml:namespace prefix="o" /><![endif]--> Not necessarily. An explosion is just a very fast fire, yes, but it also has a compressive aspect to it, due to the speed of the flame front. There will almost always be indications of heat (I say "almost", but have never seen one that didn't) and will always show, if in an enclosed space, deformation of the surfaces in an outward, although not necessarily spherical, shape. The flame front of an exploding substance is moving too fast to escape out of any openings, and will, in series, escape out of the weakest points of the enclosure, after deforming them Typically, a seam bursts, followed by tearing of a surface, with combustion residue applied to the interior surfaces. The extreme pressures are a function of the resistive strength of the material trying to contain the heat of combustion. An "explosion" in the combustion chamber doesn't deform anything, due to the strength of the cylinder wall and head, but you hear the fast-moving flame front when it escapes through the exhaust. Just my two cents worth.
Paul Rodriguez
DO NOT ARCHIVE
[quote] ---
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bill_dom(at)yahoo.com Guest
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Posted: Thu Dec 20, 2007 10:05 am Post subject: 601 and wing failiers |
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And just because a witness heard the sound of an explosion is not evidence than an explosion occurred. Other than the witness account, there is no other mention of an explosion in the report. There are reasons why NTSB takes witness accounts with a grain of salt.
Bryan:
Thanks for the warning, but I'm fully aware that real life is not like in the movies. Heck, life some times is not like in the news.
William Dominguez
Zodiac 601XL Plans
Miami Florida
ashontz <ashontz(at)nbme.org> wrote:[quote] --> Zenith-List message posted by: "ashontz"
And if there was an explosion, it's more than likely that the tank leaked somehow and fumes accummulated in the wing structure. An explosion is more likely when there's less fuel to air ratio. An outright explosion of the tank is unlikely, a small amount of fuel in the wink with a lot of air would make a bigger boom.
bryanmmartin wrote:
[quote] Just because there was no evidence of a fire does not mean there
wasn't an explosion. It is entirely possible to have an explosion
without a fire and without leaving any signs of heat damage. An
explosion does most of its damage because of the extreme pressures
produced, not from the heat. Debris from the explosion is often not
exposed to the heat for long enough to be damaged by it. Explosions in
real life don't necessarily act like they do in the movies.
On Dec 20, 2007, at 8:56 AM, William Dominguez wrote:
> I don't believe it has something to do with builder error, one of
> the failure cases was with a factory build AMD Zodiac. I don't
> believe this accident was due to an explosion as some people has
> mention, [quote][b]
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Jaybannist(at)cs.com Guest
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Posted: Thu Dec 20, 2007 10:41 am Post subject: 601 and wing failiers |
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I'm amazed at how many news reports there are of witnesses that say the airplane was on fire as it came down, when, in fact, it actually didn't catch fire until it hit the ground. I think that is probably related to the phenom where a driver speeds up when you try to pass him on the highway. It is a somewhat unconscious, unintended and unrealistic reaction to reality.
It is also common for non-aviation people to think of a stall in terms of their car engine stalling, and they are totally ignorant of the aerodynamics of an aircraft stall, and what one looks like.
Jay in Dallas
Do not archive
William Dominguez <bill_dom(at)yahoo.com> wrote:
Quote: | And just because a witness heard the sound of an explosion is not evidence than an explosion occurred. Other than the witness account, there is no other mention of an explosion in the report. There are reasons why NTSB takes witness accounts with a grain of salt.
Bryan:
Thanks for the warning, but I'm fully aware that real life is not like in the movies. Heck, life some times is not like in the news.
William Dominguez
Zodiac 601XL Plans
Miami Florida
ashontz <ashontz(at)nbme.org> wrote:
And if there was an explosion, it's more than likely that the tank leaked somehow and fumes accummulated in the wing structure. An explosion is more likely when there's less fuel to air ratio. An outright explosion of the tank is unlikely, a small amount of fuel in the wink with a lot of air would make a bigger boom.
bryanmmartin wrote:
> Just because there was no evidence of a fire does not mean there
> wasn't an explosion. It is entirely possible to have an explosion
> without a fire and without leaving any signs of heat damage. An
> explosion does most of its damage because of the extreme pressures
> produced, not from the heat. Debris from the explosion is often not
> exposed to the heat for long enough to be damaged by it. Explosions in
> real life don't necessarily act like they do in the movies.
>
>
> On Dec 20, 2007, at 8:56 AM, William Dominguez wrote:
>
>
> > I don't believe it has something to do with builder error, one of
> > the failure cases was with a factory build AMD Zodiac. I don't
> > believe this accident was due to an explosion as some people has
> > mention, the report for this accident states "no evidence of fire
> > was found" If there is a flaw in the design (I'm not sure there is
> > one), I think it is one that only comes during very specific flight
> > situation that provoke a failure when it shouldn't. Of course, this
> > are just my beliefs based on info available and they can change as
> > new info comes out.
> >
> >
> >
>
>
> --
> Bryan Martin
> N61BM, CH 601 XL,
> RAM Subaru, Stratus redrive.
> do not archive.
--------
Andy Shontz
CH601XL - Corvair
www.mykitlog.com/ashontz
Read this topic online here:
http://forums.matronics.com/viewtopic.php?p=153272#153272
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ter_turn(at)yahoo.com Guest
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Posted: Thu Dec 20, 2007 12:25 pm Post subject: 601 and wing failiers |
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I'm going to put a couple of one inch access holes in my wings and when I close them up I'll pump them full of concrete for added stiffness.
Do not archive!
Terry
ashontz <ashontz(at)nbme.org> wrote:[quote] --> Zenith-List message posted by: "ashontz"
The more I read people's input, the more I'm considering adding ribs. Granted, Zenith themselves say that you can overstress the structure with quick hard control inputs, specifically elevator. I don't think adding a few ribs would hurt or even be a big problem. In fact, I'm sure I can use the existing holes in the main spar where the hat stiffeners are to add ribs without drilling more holes in the main spar. More ribs would add more torsional strength as well as shortening the bending moments in the wing itself between rib stations. Wouldn't even be that hard to interpolate the dimensions for the new interim ribs, mostly just time making about 4 more rib forms. That with no wing locker and I think you're looking at a significantly stronger wing to make up for any possible design flaw or builder error nor would it push stress somewhere else that that stress shouldn't be going anyway. If it adds more stress to the root, oh well, that's the roots job, to hold the damn wing on!
, and in the reports there was no mention of the bolts at the root shearing. And if you wanted to beef up the root that would be pretty easy too, just add some plate to span more of the center spar and add more bolts. But that doesn't seem to be an issue.
[quote="bill_dom(at)yahoo.com"]I don't believe it has something to do with builder error, one of the failure cases was with a factory build AMD Zodiac. I don't believe this accident was due to an explosion as some people has mention, the report for this accident states "no evidence of fire was found" If there is a flaw in the design (I'm not sure there is one), I think it is one that only comes during very specific flight situation that provoke a failure when it shouldn't. Of course, this are just my beliefs based on info available and they can change as new info comes out.
William Dominguez
Zodiac 601XL Plans
Miami, Florida
Matt Ronics wrote:[quote] --> Zenith-List message posted by: "Matt Ronics"
I'll flog the dead horse with my take. I chose to build a 701 instead of 601XL over this issue. I considered a 601HD but found that the 701 was close enough to 601HD speeds to suit my needs. I've previously built a canard composite.
The issue I have with the 601XL failures is simply that they are not adequately defined. My talk with Sebastian didn't help this concern.
My totally unsubstantiated theory is that the design, as it currently exists, is intolerant of some combination of builder error. A Be a better friend, newshound, and [quote][b]
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daveaustin2(at)primus.ca Guest
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Posted: Thu Dec 20, 2007 1:38 pm Post subject: 601 and wing failiers |
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Can I suggest changing all 6061T6 to 2024T3 for greater strength and making
everything twice as thick?
Dave Austin 601HDS - 912
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psm(at)ATT.NET Guest
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Posted: Thu Dec 20, 2007 2:14 pm Post subject: 601 and wing failiers |
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Hi Dave,
I figure that would make the empty weight twice as much so you would
be over gross weight before adding any payload.
Paul
XL fuselage
do not archive
At 01:36 PM 12/20/2007, you wrote:
Quote: | Can I suggest changing all 6061T6 to 2024T3 for greater strength and
making everything twice as thick?
Dave Austin 601HDS - 912
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