Rear Fuselage Assembly

Rear Fuselage Skins

11/23/12 - Moved from sawhorses back to tables. Placed Bottom Fuselage Skin (75F1-1) on the table and attached to the Rear Bottom Fuselage Skin (75F1-2) with clecoes. Drilled and clecoed the bottom Rear Fuselage Longerons (75F2-2) to the bottom fuselage skins. Total Time = 3 hours.


Drilling Holes in Bottom Skin

  

Bottom Fuselage Skin Attached to Longerons

11/24/12 - Cut "L" Angles to size for the lateral stiffeners. Installed with clecoes to the bottom skin and drilled to proper size. Cut "L" Angles to size for the diagonal stiffeners, clecoed and drilled holes to proper size. Installed Torque Tube Bearing Channel (75F4-5) and fitted horizontal tail frames with clecoes. Cut "Z" Channels to proper size for installation around the access hole and drilled holes to proper size. Cut "L" Angles to proper size for installation on each side of the "Z" channels and drilled holes to proper size. Total time = 9 hours.

Finished Bottom Skin

11/25/12 - Installed Bottom Skin Gussets (75F4-8), drilled holes to proper size and clecoed in place. Finished drilling remaining holes in bottom skin, then removed and set it aside. Installed Rear Fuselage Longeron (75F2-2) to the Fuselage Side Skin (75F1-3) and Rear Fuselage Side Skin (75F1-4), drilled holes and clecoed in place. Total Time = 4 hours.

Longeron Attached to Passenger Side Skin

12/8/12 - Cut "L" Angles to size for the lateral stiffeners. Installed stiffeners, clecoed in place and drilled to proper size. Cut "L" Angles for the diagonal stiffeners, clecoed in place and drilled holes to proper size. Clecoed the Upright (75F3-4) and the Side Channel (75F4-1) to the Passenger Side Skin (75F1-3). Drilled out holes in Longeron (75F2-2) and attached to the Pilot Side Skin (75F1-3). Total Time = 7 hours.

Adding Upright and Side Channel to the Side Skin

12/9/12 - Cut "L" Angles for the lateral and diagonal stiffeners, drilled and clecoed in place. Clecoed the Upright (75F3-4) and the Side Channel (75F4-1) to the Pilot Side Skin. Drilled all holes to their proper size in the stiffeners and longeron. Total time = 7 hours.


Finished Pilot Side Skin

12/15/12 - Aligned the Pilot and Passenger Skin with the Bottom Skin and clecoed the H.T. Section in place. Drilled (2) locating holes on both bottom longerons. Removed the Pilot Side Skin and drilled the remaining holes in the longeron. Removed the Passenger Side Skin and drilled the remanining holes in the longeron. Reassembled the Pilot and Passenger Skins to the Bottom Skin and clecoed them in place. also placed masking tape in place for stability. Cut off excess material from the top longerons so that longerons are flush with the edge of the side skins. Clecoed the Rear Wing Attachment (75F4-4) to the Top Channel (75F3-6) and then clecoed to the side channel and the top channel. Positioned the Top Skin (75F2-1) onto the top of the rear fuselage. Clecoed the top skin into the the top channel and drilled (2) locating holes into the top longerons. Removed the Top Skin and placed on the table for drilling. Total Time = 9 hours.

Attaching Side Skins to the Bottom Skin

Drilling Holes in the Top Skin

12/16/12 - Drilled holes through the top skin into the top longerons. Opened up the holes to the proper size. Cut "L" Angles for the lateral and diagonal stiffeners, drilled and clecoed in place. Cut "L" Angles, drilled and clecoed them to the top of the H.T. Frames. Total Time = 8 hours.


Cut "L" Angles and Attached to the Top of the H.T. Frames

12/22/12 - Drilled out holes in the Top Skin to the proper size. Reattached the Top Channels to the Fuselage. Trimmed "L" angles behind rear windows by 20 mm. Attached Baggage Back Channels (75F6-7) to the Baggage Back (75F5-2). Cut three "L" Angles to 675 mm, then drilled holes in them and attached to the back of the Baggage Back with clecoes. Inserted Baggage Back into the rear fuselage. Attached the Baggage Angle (75F6-5) to the top of the Baggage Back, then drilled and clecoed baggage angle in place. Cut "L" Angles to 260 mm, then drilled and clecoed them to the Baggage Floor (75F5-3). Clecoed Baggage Floor to the Baggage Back. Total Time = 6 hours.


Baggage Back Clecoed in Place

  12/23/12 - Reattached the Top Skin to the Fuselage and fitted properly in place. Drilled holes in Horizontal Tail section and the Baggage Top. Drilled holes in the Rear Top Channel (75F3-7) and Top Channel Angle (75F3-9). Total Time = 5 hours.

 

Reattaching the Top Skin to the Fuselage

12/30/12 - Installed Top Doubler (75F4-3) onto the top skin and drilled holes to the proper size. Drilled remaining holes to the proper size in the top skin. Drilled baggage skin to the proper size. Drilled remaining holes in the rear fuselage to the proper size. Total Time = 7 hours.


Drilling Out Remaining Holes to Proper Size

 12/31/12 - Removed the Top Skin. Drilled holes in the H.T. section "L" Angles. Disassembled top skin on the table and started deburring holes. Cleaned the surface with Scotch-Brite and then coated all the surfaces with Cortec anti-corrosion. Total Time = 5 hours.



Deburring Top Skin Holes

 1/1/13 - Happy New Year! Clecoed together the top skin parts and riveted the Top Skin together and then placed it aside. Removed the Passenger Side Skin and placed it on the table. Removed all the clecoes, deburred, cleaned and applied corrosion protection to all the parts. Total Time = 7 hours.


Top Skin Riveted Together

1/5/13 - Riveted Passenger Side Skin together, then set it aside. Removed the Pilot Side Skin from the fuselage and began deburring all the parts. Finished deburring, cleaned and coated all parts with Cortec anti-corrosion. Total Time = 5 hours.

Applying Cortec Anti-Corrosion Protection

  

Side Skin Riveted Together

1/6/13 - Riveted Pilot Side Skin together and set it aside. Drilled holes for the access panel nut plates and then started taking apart the Bottom Skin. Deburred, cleaned all parts and added corrosion protection. Total Time = 9 hours.


All Bottom Skin Parts Ready for Cortec Anti-Corrosion

1/12/13 - Clecoed together the stiffeners and vaious parts to the Bottom Skin. Drilled holes for the Access Panel nut plates then riveted the nut plates to the bottom skin. Riveted all of the stiffeners and parts to the bottom skin. Filed down the edge of the Flap Motor Mount (75C1-1) so that it would fit in between the longeron and the "Z" channel on the passenger side of the bottom skin. Aligned the mount and drilled the appropriate size holes in the Flap Motor Mount and the bottom skin. Removed the mount to be installed at a later time. Total Time = 6 hours.


Bottom Skin Riveted Together

1/27/13 - Riveted the "L" Angles to the top of the H.T. Frames Clecoed the Passenger and Pilot Side Skins to the Bottom Skin. Positioned the Top Skin on top of the fuselage and clecoed it in place. Riveted the Side Skins to the Top and Bottom Longerons. Attached the top doublers to the Top Skin with clecoes. Total Time = 5 hours.


Clecoing the Side Skin in Place

 

Riveting the Fuselage Together

 

The Time Tunnel (Inside of Fuselage)

 

Completed Rear Fuselage

 Total Rear Fuselage Assembly Time = 102 hours.

Wings Continued - Right Wing

Right Wing Assembly



Skeleton Riveted Together

7/21/12 - Assembled Right Wing Skeleton with clecoes and riveted it together. Cut "L" Angles to size that will fit inbetween the rear ribs, drew a centerline and drilled a starting hole that was 10 mm from the end. Drilled holes in the Bottom Skin (75W6-1) and through the "L" angles. Clecoed "L" angles in place and fitted bottom skin to the wing skeleton. Total Time = 6 hours.


Drilling Holes to Proper Size

 7/22/12 - Clecoed bottom skin in place and drilled out all holes to the proper size. Installed Inboard Trailing Edge Skin (75W6-3), Outboard Trailing Edge Skin (75W6-4), Inboard Nose Skin (75W5-1), Outboard Nose Skin (75W5-2) and clecoed in place. Dilled out all holes to proper size in the spars and ribs. Clecoed Flaperon Brackets in place and drilled holes in the Flaperon "L" brackets. Total Time = 5 hours.

All Skins in Place

Installed Strut Brackets



7/28/12 - Installed strut brackets and drilled holes into the bottom skins as well as into the brackets. Set aside brackets to be riveted at a later time. Total Time = 3 hours.


Adding Cortec Anti-corrosion Material



7/29/12 - Removed all skins from the wing skeleton and deburred the wing skeleton. Deburred all skins and "L' angles. Cleaned all parts and added Cortec anti-corrosion protection. Reassembled skins to the skeleton with clecoes. installed rivets into the holes and riveted all skins to the bottom of the wing. Total Time = 12 hours.



Riveting the Skins



Bottom Skin Riveted in Place

 8/4/12 - Drilled holes in the "L" angles and clecoed them to the underside of the top skin (75W5-4). Clecoed the Flaperon Brackets to the wing skeleton.


Top Skins Clecoed to Skeleton

8/4/12 - Installed the top skin and the tank cover skin (75W5-3) to the wing skeleton and clecoed in place. Measured 70 mm from the trailing edge to the flaperon arm. Drilled holes in the trailing edge skin and clecoed in place. Drilled out all of the holes in the top skins to the proper size. Total time = 4 hours.



Leading Edge Top Skin Ready to be Pulled Over Ribs

8/11/12 - Pulled the Leading Edge over the main wing spar with straps and drilled holes in the skin to the proper size. Removed the top skin, tank cover skin and deburred the wing skeleton. Total Time = 7 hours.


Deburring Skeleton

Deburring Sharp Edges on the Tank Cover Skin

8/12/12 - Deburred the Top Skin and the Tank Cover Skin and added corrosion protection. Riveted the Flaperon Brackets in place and finished adding corrosion protection to the wing skeleton. Riveted the Tie-Down Bracket and the Rear Attach Bracket to the Wing Skeleton. Total Time = 5 hours.


Riveting Flaperon Brackets

All Brackets Riveted

9/2/12 - Cut cork to the proper size and applied to the fuel tank. Fitted fuel tank into wing and made adjustments as necessary to get a proper fit. Total time = 5 hours.

Fuel Tank Fitted Into Place

9/3/12 - Cut a hole in the fuel tank with a flycutter for the sender unit to fit into. Installed the fuel channel (75K1-2) into the wing skeleton. Installed the tank cover and drilled holes into the fuel channel and cover and clecoed in place. Cut "L" angles and installed them into the wing tip area. Total time = 6 hours.


Cutting Hole in Fuel Tank with Flycutter

Installed the Nose Rib (75W4-1) and riveted in place. Installed the Root Rib Doubler (75W4-3) and riveted in place. Flattened one end of the Root Rib Angle ( 75W6-5) and then crimped to follow the curvature of the Root Rib. Installed the Root Rib Top Skin (75W5-5), drilled holes and clecoed in place. Total Time = 7 hours.


Root Nose Rib and Doubler Riveted in Place

9/9/12 - Installed the Wing Tip (75W6-8), drilled holes and clecoed in place. Total Time = 3 hours.



Drilling the Wing Tip and Clecoing in Place 

9/16/12 - Installed the sender unit (226-451D) inside the fuel tank. Installed the Nav/Strobe light in the end of the wing tip. Also enlarged the hole in the bottom of the wing for a better fit for the fuel drain. Total Time = 5 hours.


The Nav/Strobe Light Installed

 9/21/12 - Attended Zenith's 20th Anniversity Open Hanger Event in Mexico, Mo. Gathered lots of valuable information about painting the aircraft after completion and different engine choices for the CH750. Also attended the Friday night banquet in which Rod Hightower spoke on behalf of the EAA.



Open Hangar Day

9/22/12 - Had a chance to talk to fellow Zenith builders which was invaluable. Learned more about the Jabiru, UL Power and Viking engines. Was quite impressed with the Viking fuel-injected engine so much so that I decided to take a Demo flight with the owner of Viking, Jan Eggenfellner. After that flight, I was sold. It was very powerful and did not have the vibration that I expected or excessive noise either. I had finally decided on the powerplant for my build!

Viking Powered CH750 Demo Plane

9/28/12 - Found out that I could upgrade to Edition 3 CH750 while I was at Zenith last weekend. This upgrade includes a smoked glass aerodynamic top window. Recived the upgrade kit from Zenith today and I can't wait to start installation on Saturday.

9/29/12 - Removed the old Root Rear Rib (75W4-2) by drilling out the bottom rivets and Root Rib Doubler and installed the upgraded Root Rear Rib (75W4-2/1). Total Time = 2 hours.



Look at the Difference Between Root Ribs

  10/6/12 - Since I have decided on using the Viking engine with a header tank, I installed a pipe plug in the return line port of the fuel tank. Also placed cork on top of the fuel tank so that it doesn't rub on the fuel tank top skin. Installed the new Wing Root Top Skin (75W5-5/1). Total Time = 2 hours.


New Root Rib Installed

10/7/12 - Dilled out rivets on the bottom of the wing to accomodate the new Wing Root Nose Skin (75W5-6). Installed new nose skin and pulled tight to drill new holes into the new Wing Root Rib. Drilled all holes to their proper size, deburred, cleaned and applied anti-corrosion protection. Opened up hole in the fuel tank top skin with a file so that it doesn't touch the gas cap. Installed cable clamps  into the rear spar for the wiring of the Nav/Strobe & Landing Lights. Total Time = 8 hours.

Cable Clamps in Place

Nav/Stobe Light Wired In

10/20/12 - Opened up hole in the rear spar so the fuel supply grommet could be installed. The fuel hose was then routed through the grommet and exited out the back of the rear spar. Attached the fuel hose to the supply nipple with the supplied radiator style hose clamp. Drilled out machining hole in the rear spar and installed the grommet for the sender unit wire. Wired up the Nav/Strobe light and and verified the continuity of the wires at the root end of the wing. Bolted the strut support bracket into place and riveted the bracket assembly to the bottom of the wing. Total Time = 11 hours.


Fuel Hose Routed from Tank Through Rear Spar

Strut Support Bracket Assembly Riveted to Bottom of Wing

10/21/12 - Replaced a cracked fiber washer on the fuel tank sender unit attaching screw. Wired up the fuel sender unit and attached the ground wire to the fuel tank grounding lug on the sender unit and the tank. Riveted the ground wires to the root rib. Added more cork to the fuel tank and installed the tank in the wing skeleton. Riveted the fuel channel in place and then pulled the nose skin over with straps and clecoed nose skins in place. Began riveting the nose skin at the top middle part of the leading edge. Total Time = 8 hours.



Fuel Tank Wiring in Place.

10/27/12 - Verified the Landing Light wiring. Drilled a hole in the Nose Skin and installed a grommet for the Landing Light wiring to pass through. Finished riveting the rest of the Right Wing. Removed the Left Wing from the brackets on the wall and placed it onto the sawhorses. Hoisted the Right Wing onto the brackets on the wall. Total Time = 7 Hours.

Landing Light Grommet in Place



Completing the Riveting



Finished Right Wing

Right Wing Hung on the Wall

Right Wing Total Assembly Time  = 122 Hours.