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New style wingtip on 601XL

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z601(at)anemicaardvark.co
Guest

Posted: Thu Feb 05, 2009 2:37 pm Post subject: New style wingtip on 601XL

This posting is intended to share information, in case someone else runs into 

the same problem. I sent the following query to Zenith this morning:



"I am building 601XL S/N 7410. I have found what may be a discrepency between

the drawings and the packing list/parts shipped. 



According to your web site (zenithair/com/zodiac/xl-update-4th-ed-1-08.pdf),

I have the most current revision of drawing 6-W-9. It is dated 01/08. This

drawing shows the wingtip to the finished with a wingtip top angle

(6-W-9-7), a wingtip bottom angle (6-W-9-6), a wingtip sheet (6-W-9-4), and

a fiberglass tip (6-W-9.5).



Of the above items, the packing list shows only the 6-W-9-5, but lists it as

"fiberglass wing tips, full." This matches what appears to have been

delivered. This part appears to extend the full length of the wing tip.



However, there drawing 6-W-9 does not reflect how this part is to be

installed. It appears there may be, or may need to be, an update of this

drawing to reflect the new tip. 



Please advise me on what is correct, and what drawing revision is to be

used."



This is Zenith's response - within a couple of hours, I might add:



"What you have found is a transitional issue between the 601XL and the 650.

The fiberglass tips are considered a 650 part that we experimented with on

the 601XL before the 650 was released. I have attached the corresponding 650

drawing that covers the installation of the tip.



Caleb Gebhardt"



While I think Zenith is as human as anyone else, and just as capable of 

mistakes, I am favorably impressed at the speed and thoroughness of their 

response.

=============================================

                Jim B Belcher

    BS, MS Physics, Math, Computer Science

                  A&P/IA

     Retired aerospace technical manager

=============================================

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Afterfxllc(at)aol.com
Guest

Posted: Thu Feb 05, 2009 2:50 pm Post subject: New style wingtip on 601XL

They made about 7 or 8 changes that the drawings are out dated on and even  their web site don't reflect. You have the new style one piece wing tips and it  replaces all the other parts. 

  

 One other change is the rear spar channel upright that used to go thru the  baggage floor and you had to make a cut out for it but now they have shortened  the channel and doesn't have to be cut out. 

  

 Other changes are the rear upper rudder attach plate is thicker.

 the center seat bottoms didn't fit (Called Roger and I think they changed  them)

 Upper shoulder harness attach isn't the same as the drawing no reference  how to install.

 the NEW BRS bracket didn't fit had to modify it. Again no drawing but they  sent me one.

  

 If you get stuck on anything give me a call

  

 502-644-8123

  

 Jeff

 Great Deals on Dell Laptops. Starting at $499.

  [quote][b]

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Thruster87

Joined: 16 Apr 2008
Posts: 193
Location: Australia

Posted: Thu Feb 05, 2009 8:25 pm Post subject: Re: New style wingtip on 601XL

Any chance of posting that drawing as I'm nearly at that stage of installing the new wing tip as well. Thank you T87

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PatrickW

Joined: 27 Oct 2006
Posts: 380
Location: Fort Worth, Texas

Posted: Fri Feb 06, 2009 10:40 am Post subject: Re: New style wingtip on 601XL

 	  Afterfxllc(at)aol.com wrote: 	
		   the NEW BRS bracket didn't fit had to modify it. 	




How so, with the new BRS bracket not fitting...?  



Was that the front bracket (that doubles as an engine mount attach point) or a rear bracket (which wasn't included in my kit but I'm fabricating myself)?



Thanks



- Pat

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Afterfxllc(at)aol.com
Guest

Posted: Fri Feb 06, 2009 11:56 am Post subject: New style wingtip on 601XL

Pat

  

  It was the front bracket. I had to cut the front of it and make it  like the older brackets. Zenith had bent it at the wrong angle and it when  mounted it stuck out on the sides of the longerons.   The part of  it that was bent wrong was where it bolted to the firewall. I had to cut that  part out to allow it to pivot closer to the firewall thus bringing it even with  the longerons.

  

 Jeff

  

 Great Deals on Dell Laptops. Starting at $499.

  [quote][b]

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Larry Hursh

Joined: 16 Feb 2008
Posts: 125
Location: Edwardsburg, MI (near Elkhart, IN)

Posted: Fri Feb 06, 2009 7:01 pm Post subject: Re: New style wingtip on 601XL

Jim,  I finished installing the new style wing tips a couple of months ago.  At that time, I don't think there was any print or write ups on it.  I also talked to Caleb about the installation.  One thing I knew for a fact was, fiberglass doesn't usually hold it's molded shape unless it is thick and/or strongly reinforced.  Of course, these wing tips are not thick by any stretch of the imagination and mine didn't hold their original shape either.  If you have trouble with the parts not lining up or a flat edge not being so flat, use a heat gun on it as I did.  Stay back from the part and heat it up slowly.  Gently over pull it to where you want it to be then hold it there.  Be sure to use a shop towel because its going to be hot.  Don't overstress it, otherwise it WILL crack!!  When it cools, it should shrink back some and will be hopefully exactly where you need it to be.  



One other thing I did was, I cut an "L" angle and reinforced the wingtip inside the wing.  I "sandwiched" the bottom of the wingtip between the bottom skin and the "L" angle (on top).  It worked like a charm - I got a nice, straight edge.  



My EAA Advisor/DAR suggested I also chalk around the entire wingtip.  I bought a tube of Dupont 7500 chalk at my local auto paint store.  It's water soluble and can be cleaned off with soap and water.  It can be painted.  



Hope this helps you out.

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80.JPG

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One fiberglass wingtip drilled and clecoed into place

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_________________
Larry Hursh (N650LM Reserved)

"One rivet at a time......one day at a time.."

CH650 (Converted from CH601XL)
1/2 done with fuselage
will be Corvair Powered

z601(at)anemicaardvark.co
Guest

Posted: Sat Feb 07, 2009 7:04 am Post subject: New style wingtip on 601XL

On Friday 06 February 2009 21:01, skyridersbn wrote:

Many thanks for the hints. You have addressed some of the concerns I have. The 

fiberglass Zenith uses is really lighter than I feel is best. I will likely 

install the reinforcements you suggest.



I was tempted to fabricate the old parts, and use them. I may try the new 

parts, with the old parts as a backup plan, just in case. I'm somewhat 

concerned about the weight of the strobe on the wingtip, because (even though 

Zenith puts it there) it really just looks too lightweight to support much of 

anything.

 	  Quote: 	
		  

 Jim,  I finished installing the new style wing tips a couple of months ago.

  At that time, I don't think there was any print or write ups on it.  I

 also talked to Caleb about the installation.  One thing I knew for a fact

 was, fiberglass doesn't usually hold it's molded shape unless it is thick

 and/or strongly reinforced.  Of course, these wing tips are not thick by

 any stretch of the imagination and mine didn't hold their original shape

 either.  If you have trouble with the parts not lining up or a flat edge

 not being so flat, use a heat gun on it as I did.  Stay back from the part

 and heat it up slowly.  Gently over pull it to where you want it to be then

 hold it there.  Be sure to use a shop towel because its going to be hot. 

 Don't overstress it, otherwise it WILL crack!!  When it cools, it should

 shrink back some and will be hopefully exactly where you need it to be.



 One other thing I did was, I cut an "L" angle and reinforced the wingtip

 inside the wing.  I "sandwiched" the bottom of the wingtip between the

 bottom skin and the "L" angle (on top).  It worked like a charm - I got a

 nice, straight edge.



 My EAA Advisor/DAR suggested I also chalk around the entire wingtip.  I

 bought a tube of Dupont 7500 chalk at my local auto paint store.  It's

 water soluble and can be cleaned off with soap and water.  It can be

 painted.



 Hope this helps you out.



 --------

 Larry Hursh (N650LM Reserved)

 CH650 (Converted from CH601XL)

 Starting fuselage

 will be Corvair Powered




	


=============================================

                Jim B Belcher

    BS, MS Physics, Math, Computer Science

                  A&P/IA

     Retired aerospace technical manager

=============================================

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