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Heart attack averted

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naumuk(at)alltel.net
Guest

Posted: Mon Apr 03, 2006 3:46 pm Post subject: Heart attack averted

All-

    I've had a lot of off-list questions about the latest bump in the road, and rather than try to answer them individually, here goes- get in for a long story!

    This was a case where there was no glaring mistakes that jump out and grab your eye until it seems that it's too late. It's known as cumulative error. A combination of factory error, then procedural error, finally doubled by a visit from Mr. Murphy.

    From the HDS builder's manual for the center wing- "Clamp the L Angle at STA. 900 and 1014 over the pre-drilled holes in the Spar caps. Next clamp the (Nose) rib to the L Angle and check the alignment of the pre-drilled holes in the Spar Web with the Rib flange. Back drill with #20."

    When I did this, the web holes were off center with the starboard gear inboard nose rib flanges (The web holes were off by 3mm)  but still legal. We've all been there. That's great for the the nose ribs, but your rear gear ribs are locked in with no slack.

    When I started working with the rear ribs, I found that the A6 holes barely showed contact with the inboard edge of the doubler. The gear rib alignment checked out, so I measured the A6 holes. The starboard side was right on the money by my calculations, but the port was inboard by 7mm. I triple checked everything, then decided my best course of action was to drill holes to the centerline of the port doublers, and contacted Zenith as to how best fill the extra holes.

    Moving back around to the nose side, I made nose rib adjustments TO THE WRONG SET OF HOLES, doubling the error. It wasn't until I set the rear bottom skin, straigthening up all the ribs until they were square and perpendicular, that the problem was noticable. This is why my picture looks so hideous.

    Bottom line- I'll have 2 sets of A6s in the inboard gear rib flanges, and will make .025 doubler strips for both front and back of the affected web flange, but we're back on the road.

    Amazing how two holes can damn near ruin the next couple of months!

                                                                    Bill

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jf701(at)bellsouth.net
Guest

Posted: Tue Apr 04, 2006 3:55 am Post subject: Heart attack averted

"...  Bottom line- I'll have 2 sets of A6s in the inboard gear rib flanges, and will make .025 doubler strips for both front and back of the affected web flange, but we're back on the road.     Amazing how two holes can damn near ruin the next couple of months!"



Bill:



The two truth-isms that I've learned during my project (I think from this same list server ) are   



"The best measure of a builder's ability is not is his ability to avoid mistakes but rather his ability to gracefully recover from them." 



and



"Perfectionists build, and Builders fly".



John Flavin

CH701 60%,  Raleigh, NC (soon to be Overland Park, KS)

do not archive

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naumuk(at)alltel.net
Guest

Posted: Tue Apr 04, 2006 2:15 pm Post subject: Heart attack averted

John-

    Don't know if I'll ever be "Graceful" about finding an error. More like 

"Not again!"

    Thanks big time to you and all my list friends. I've aquired a number of 

OCDs from my project, not the least of which is self-doubt.

    I disagree with your last quote. You can be both- on your SECOND 

project.

                                                                  Bill



                                    do not archive

---

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