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601HDS: O/BWing - Aileron photo request (ZAC Plans attack!)

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Mitch Hodges

Joined: 10 Jan 2006
Posts: 45
Location: Powder Springs, GA

Posted: Mon Apr 09, 2007 8:42 am Post subject: 601HDS: O/BWing - Aileron photo request (ZAC Plans attack!)

First some good news.  After way too long  (we're talking years) I finally finished an outboard wing!  It's good to make some progress.



Now the bad news, and a request (along with an excuse).   I built my ailerons several years ago following the hand-drawn plans available at the time. Even with kit parts, it seems I managed to screw them up.  I misread the plans and matched the inboard end rib of the aileron (where the aileron crank attaches) to the inboard wing rib rather than just following the "line" of the wing rib.  So, when I recently fit it to the completed wing, I cut it the aileron too short on the inboard side.  Rather than being past the end of the rear zee, I cut it at the inboard rib.  (OUCH!).  There goes about $200 worth of parts.



While I lick those wounds, I'm going to trudge forward with the left wing while I save my pennies.  



Does anyone have a good photo of the clearance required between the aileron and the rear zee, on the inboard side of an HDS?  I want to make sure when I get to the left one I don't make the same mistake.



Also, I already know the left aileron ribs are in the "wrong" location but I can still cut the aileron to the right length.  Basically, the aileron rivet lines will not line up with the wing ribs (they'll shift 4 or 5 inches inboard), and the larger gap will be on the outboard edge, rather than inboard.  I've got that question into ZAC, but any thoughts here rather than cosmetically if there would be any concerns with that?



Thanks,

Mitch Hodges

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_________________
Mitch Hodges
N601MH (Zenith 601HDS)
Builder Log at http://www.hodges.aero
Wings Under Perpetual Construction

naumuk(at)alltel.net
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Posted: Mon Apr 09, 2007 2:46 pm Post subject: 601HDS: O/BWing - Aileron photo request (ZAC Plans attack!)

Mitch-

    1. The natural tendency that early in the game is to build the small 

parts first. You just found out what I did the first time around- you build 

the ailerons to fit the wings, not vice versa.

    2. Clearance between the aileron and rear zee? The hinge tab is 40mm 

from the forward edge of the aileron skin/aileron rib. The difference is 

20mm from the rivet line of the wing Z spar and the rivet line of the 

forward part of the aileron.

    3. The only way you'll spend $200 on a new set of ailerons is if you 

haven't already built a Home Depot (Or similar) brake. More like less than 

$75.00.

    4. The one place I screwed up second time around was forgetting to 

compensate for the aileron twist when laying out my rivet lines. 

Consequently, my top rivet line is right on the money, but the bottom fades 

outboard by 2-3mm.

    Pictures attached. Hope they help. Talk about old- they're from 1 

workshop and 2 cordless drills ago! Hang in there...

Bill Naumuk

HDS Fuse/Corvair

Townville, Pa

---

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mitch(at)HODGES.INFO
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Posted: Mon Apr 09, 2007 4:00 pm Post subject: 601HDS: O/BWing - Aileron photo request (ZAC Plans attack!)

Thanks Bill.  The pictures definitely help.    I'd still like to see a

close-up of the I/B section right where the aileron and the rear zee end if

someone has one though.  Some other thoughts:



"Clearance between the aileron and rear zee?"



What I really meant was where does the inboard end of the aileron line up

with the inboard end of the wing.  From your pictures, it looks like it is

right at the I/B end of the rear zee at the point where the splice plate

forms the base of the triangle.  That is what I thought.  I see now also

from the plans you trim the splice plate for clearance in a later step.



"The only way you'll spend $200 on a new set of ailerons"



Or you buy the parts from Zenith directly.  That is about what it adds up to

when you order the parts.  The ribs are about $15 each and the skin is well

north of $100.  I'm going to let that sit a while but I'm willing to bet I

end up scratch building those replacements!



"The one place I screwed up second time around was forgetting to compensate

for the aileron twist when laying out my rivet lines."



Oh, I did that the first time, I guess we reversed ordered our misses!

<grin>



Mitch Hodges

601HDS  (working on outer wings)

http:\\www.hodges.info

Powder Springs, GA

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naumuk(at)alltel.net
Guest

Posted: Mon Apr 09, 2007 5:26 pm Post subject: 601HDS: O/BWing - Aileron photo request (ZAC Plans attack!)

Mitch-

    1. I'd like to find out where you're ordering HDS parts. Nothing on the 

website lately.

    2. You'll never see the picture you're talking about on an unfinished 

plane. Per the plans and manual, (sic) "Leave extra and cut to fit." You 

still have to carve a big chunk out of both the outboard wing and c-section 

to achieve the ( I hate to call it this, but can't think of any other term ) 

dihedral angle and clearance for assembling the spar bolts. Check out Larry 

McFarland's website.

    Every project's just a little different. That's why in some cases, 

Zenith couldn't give a hard figure.

Bill Naumuk

HDS Fuse/Corvair

Townville, Pa

---

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mitch(at)HODGES.INFO
Guest

Posted: Mon Apr 09, 2007 6:04 pm Post subject: 601HDS: O/BWing - Aileron photo request (ZAC Plans attack!)

"I'd like to find out where you're ordering HDS parts. Nothing on the 

website lately."



If you call them directly they'll still sell you parts.  I've ordered a 

wingtip rib in the last couple of months (snipped it when trimming the top 

rear skin) and they gave me pricing when I called to verify my mistake on 

Friday.



Mitch

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naumuk(at)alltel.net
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Posted: Mon Apr 09, 2007 6:22 pm Post subject: 601HDS: O/BWing - Aileron photo request (ZAC Plans attack!)

Mitch-

    I mean a listing of available parts. I hope I don't need any more at 

this point, other than maybe my third right outboard fiberglass tip!

Bill Naumuk

HDS Fuse/Corvair

Townville, Pa

---

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Mitch Hodges

Joined: 10 Jan 2006
Posts: 45
Location: Powder Springs, GA

Posted: Tue Apr 10, 2007 3:45 am Post subject: Re: 601HDS: O/BWing - Aileron photo request (ZAC Plans attac

 	  naumuk(at)alltel.net wrote: 	
		  I mean a listing of available parts.....--- 	




Your right, I couldn't find the online listing either when I went looking, which is why I called them.  They do still list the full kit price and the subkit prices at http://www.zenithair.com/zodiac/6-price.html



Mitch

Do Not Archive

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_________________
Mitch Hodges
N601MH (Zenith 601HDS)
Builder Log at http://www.hodges.aero
Wings Under Perpetual Construction

naumuk(at)alltel.net
Guest

Posted: Tue Apr 10, 2007 2:22 pm Post subject: 601HDS: O/BWing - Aileron photo request (ZAC Plans attack!)

Mitch-

    I can live with being able to call and get a quote for a specific part, 

but the online list was nice.

Bill Naumuk

HDS Fuse/Corvair

Townville, Pa

---

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mitch(at)HODGES.INFO
Guest

Posted: Tue Apr 10, 2007 7:03 pm Post subject: 601HDS: O/BWing - Aileron photo request (ZAC Plans attack!)

Just to complete the picture, here's a shot of my goof.  Hopefully, others 

will learn from it.   Read the plans 100 times then look for a photo!  As a 

reference, the O/B end is already cut and fits perfectly.



Thanks everyone for your help and responses.  If you have a photo that 

matches this shot, but the "right" way I would appreciate a copy.



Mitch

---

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