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PatrickW
Joined: 27 Oct 2006
Posts: 380
Location: Fort Worth, Texas
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 Posted: Sun Mar 30, 2008 6:45 pm Post subject: XL: Center Spar vs Side Skin Cutouts |
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Fitting the fuselage side skins...
Everything appears to fit except for the pre-cut slots in the fuselage side skins (where the wings insert into the center spar). Either the center spar is at an incorrect angle, or the slot in the side skins are at the wrong angle. The rest of the holes in the skins look dead-on, and the longerons are level.
It's off by quite a bit. Pictures here: http://picasaweb.google.com/Patrick.Hoyt/XLSideSkins
I measure the angle between the center spar and the floor at 77 degrees, and the angle between the center spar and the upper longerons is 81 degrees. Does that match what you guys have...?
Anybody else ran into anything like this...?
Thanks,
Patrick
XL/Corvair
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sonar1@cox.net
Joined: 02 Oct 2007
Posts: 55
Location: Santa Barbara, Ca
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| Posted: Sun Mar 30, 2008 8:22 pm Post subject: Re: XL: Center Spar vs Side Skin Cutouts |
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I thought it was just me. Mine from the complete kit didn't fit. The cutout was at 81.9 degrees instead of 81. I called Caleb at the factory and he said that it was close enough.. I ended up redoing both side skins to the plans. Is everyone else just forcing the center spar to fit??
do not archive
Fred Sanford Ca. N9601 99%
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Aerolitellc(at)aol.com
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| Posted: Mon Mar 31, 2008 12:05 am Post subject: XL: Center Spar vs Side Skin Cutouts |
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Whenever I order a kit from Zenith I ask them what "improvements" have you made. I told them not to cut the side skins because I have templates I use to make the cut outs that I know are correct. One area they cut out on the skin that is a problem if your not careful is the lower front of the side skin where it wraps around the fire wall. If you aren't careful and don't get the firewall tight to the lower skin the side skin will be too short and the pre punched holes of the lower skin will be even with the side skin lower edge and there is nothing you can do to fix it except make a new skin and trim to fit. I told zenith they should leave extra there but I don't know if they did or not but mine will come uncut.
A lot of the problems they seem to be having has stemmed from them changing their motor mount it seems to me.
Jeff
In a message dated 3/31/2008 12:26:35 A.M. Eastern Daylight Time, sonar1(at)cox.net writes:
| Quote: | I thought it was just me. Mine from the complete kit didn't fit. The cutout was at 81.9 degrees instead of 81. I called Caleb at the factory and he said that it was close enough.. I ended up redoing both side skins to the plans. Is everyone else just forcing the center spar to fit??
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Create a Home Theater Like the Pros. Watch the video on AOL Home.
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PatrickW
Joined: 27 Oct 2006
Posts: 380
Location: Fort Worth, Texas
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| Posted: Mon Mar 31, 2008 7:47 am Post subject: Re: XL: Center Spar vs Side Skin Cutouts |
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| sonar1(at)cox.net wrote: | | I thought it was just me. Mine from the complete kit didn't fit. The cutout was at 81.9 degrees instead of 81. I called Caleb at the factory and he said that it was close enough.. I ended up redoing both side skins to the plans. Is everyone else just forcing the center spar to fit?? |
It's off by too much to force the spar to fit. Metal would have to be bent. Plus there's two rivet lines on the skins leading up from the center spar that will presumably be off, since they are parallel to the cutout.
Longerons are bolted to the motor mount, and they are level, so there's no question of inaccuracy on that end.
I think I'll have to call Zenith and see what they say...
Patrick
XL/Corvair
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DaveG601XL
Joined: 27 Oct 2006
Posts: 351
Location: Cincinnati, Oh
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| Posted: Mon Mar 31, 2008 8:23 am Post subject: Re: XL: Center Spar vs Side Skin Cutouts |
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Patrick,
So are you saying that if you measure the angle between the side skin cutout and the top edge that it is not 81 degrees?? My pre-cut side skin was correct at 81 degrees (purchased 02/07).
I know that ZAC has mis-cut or mis-drilled some stuff, but only because of other poster's comments. In my personal case, everything from ZAC seems to have been made correctly. In cases where I found problems similar to yours, it ended up that I was the one at fault. After I reviewed all drawing characteristics, I could point to where I screwed up and was glad to have had something, like a pre-cut, to point out my mistake. If I was a scratch builder, I would have scrapped out a lot more aluminum than I did as a kit builder. Triple check your measurements and angles to the drawing on both your spar placement and the pre-cut skin. Pay particular attention to the cabin floor angle. This caused me problems.
My biggest problem with ZAC was where they had made changes to the product, incorporated them on my hardware, but did not update the drawing. This caused many a head scratch until I was able to get a hold of ZAC and they told me of the change.
Good luck on a resolution,
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David Gallagher
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