We only spent an hour on the left wing. The rear channel positioning template was used for the first half of the drilling. Attaching the inboard halves still needs to be done, and the rear channels do need to be trimmed to fit.

Project Status:
Wings: 30.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~133 hours

Sunday was busy even though only about 3 hours of work got done.

Dave and Pat from EAA dropped by to see what a Zenith project is all about. They are about to embark on the journey with a 601XL.

The 60mm jig worked perfectly, and I did drill the channels into place from the middle of the spar outwards, but did the middle heavy channel last. I did have to trim the rib channel position template a small amount.

Everything seems to be square.

For the middle heavy channel, we used two bookshelf brackets ( as pictured ) to keep the ribs square as the rib angle and channel were squared into place. We had to mark the holes into the rib angle and then precision drill them since clamping would have been impossible.

The left wing's rear channel should not take near as long.

Saturday we actually flew the old 150 and saw the new Olympic Sculpture Garden from the air.


Project Status:
Wings: 29.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~133 hours

Finally got a little time to work on the project. Spent about and hour playing with the rear template placement jig and the rear channels.

When I had my last major question, I was trying to determine the jig distance for the rear channel ( 380 or 400mm ). I called Zenith and Roger gave me a better way: do not even use the jig. His suggestion was ( working center outwards ) to square the ribs, place the wing channels and THEN drill the angle to the channels.

Having already jigged the long sets, I decided to do this for the short channel.

Here is the problem: I first test fitted the 600mm channels and the angle ( 7V6-3 ) was not protruding far enough from the channel. The mating surfaces were about 3-4 mm apart. The obvious fix is to trim away a small portion of the flange from the wing rib. Because the piece must be 600mm for proper rib alignment, moving the 7V6-3 or the fabricated end cap are not options.

I'm still going to follow Roger's advice for the shorter channels since I can trim the entire channel for clearance before adding the 7V6-3 and still maintain proper edge distance.

Project Status:
Wings: 26.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~130 hours

We spent about four hours fabricating the rear wing channels for the left and right wing.

The manual gives a kernel of a good instruction, but there was an easier way. If you mark the edge distance and then mark your rivet holes on the outside of the channel, you can support the piece ( placed in the jig ) during drilling with a small piece of wood underneath it. When you back drill, use the same piece of wood with a clamp to keep parts from shifting.

The first jig was set to a length of 600mm for 7V6-2SP. The manual states that for 7V6-1 the jig should be set to 380mm, BUT the length of 7V6-1 is 380mm. The plans state that the flange-to-flange distance of the completed part is 400mm, so I think the manual is in error.

The Zenith list seems to concur, but I'm going to call Mexico, MO in the morning.

Also, Robert from my EAA chapter dropped by curious to see what the Zenith build process id like compared to the RV-7 he is working on.

Project Status:
Wings: 25.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~129 hours

The amount of wood used so far to make an "all aluminum plane" has probably been enough to make a Fly Baby.

We spent about two hours cutting the false rib template and making the first rear channel jig ( both shown in the photo ). Most of that was figuring out the fancy new tool. It even can with an instructional DVD.

The router also came in handy cleaning up the workbench edge that 1) wasn't cut very straight 2) has been drilled more than Paris Hilton.

Project Status:
Wings: 21.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~124 hours

Thursday night was spent laying out the false rib template.

This was an easy task, except on the plans many of the measurements are relative to each other, making some easy parts hard.

More tools are needed... like a router to do the tight spots. Should also come in handy for the slat jig.

Project Status:
Wings: 19.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~122 hours

On Monday we spent about an hour fabricating the bends in the rear channel for the right wing. Wood was used instead of a backing bar. I used a file to bevel of the edge for the radius to be about the correct size.

Project Status:
Wings: 18.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~121 hours

Saturday consisted of powertools and football. As an added bonus the Cowboys snatched defeat from the jaws of victory.

We spent 4.5 hours fabricating the skin supports for the left wing, drilling the supports, mounts and tip ribs. Everything got deburred, protected and riveted. For both wings. It was a large amount of work for very little visual payoff.

The next mini-project is the rear wing channel. This will involve some templates and a simple jig.

Project Status:
Wings: 18.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5 )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~120 hours

I spent about an hour and a half fabricating the skin supports for the ribs that also have the slat brackets.

The whole affair was straight forward, but I found it slightly difficult to drill the bend release holes. Getting a good angle to cut the L angle was also a little tricky.

Only the right side was fabricated so I could avoid any problems of mirrored parts getting mixed up.

Someone asked me if I worked on the project every night... and recently I have been. But there was a while when work prevented such progress. Even if I don't actually drill, cut, deburr or corrosion protect something, working at least every other night keeps the project in your mind and avoids having to REALLY spend some time reorienting yourself.

Project Status:
Wings: 14h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5 )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~115.5 hours

I spent about an hour making the slat placement template tool. The extrusion came from Home Depot and the 1/8" plate came from Ballard Sheet Metal Works. Most of the time was spent using the hacksaw on the plate. The plate is 7000 series and really hard stuff. A little extra time was spent using scotchbrite on the extrusion to obtain a nice brushed metal look. One small deviation from the plans was made: I riveted a small piece of plate between the extrusion at the end of the tool to maintain a constant gap between the extrusion and provide for better stability.

What is a massive project that takes years to finish? An airplane yes, but also a video game. I am preparing for another crunch at the office, but you can see the fruits of my labor. If you have a Xbox 360 with a Xbox Live Gold account and a Xbox hard drive, then please sign up for the Shadowrun beta. http://shadowrun.com/behindthescenes/articles/BetaApplication.htm

Should you accept the offer from Mr. Johnson you will be given the chance to geek those dandelion eaters without having to pay any Nuyen to enter the matrix.

Project Status:
Wings: 12.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~114 hours

An hour and a half was spent drilling the left wing. The rear ribs, spar tip, and root ribs were all drilled into place.

Next is the slat placement template. I need to stop by the metal shop in the morning to get some aluminum plate ( t=.125, 80mm x 150mm )

There are some things the every good workshop should have... like an iPod. Seriously, having every CD you own in something in the equivalent volume of a CD case is perfect for keeping in the shop.

In other good news: http://www.can-zacaviation.com/floats/floats.htm

Project Status:
Wings: 11.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~113 hours

We spent only an hour today, but managed to get the tip ribs drilled into place for the left wing. A friend was over helping with the build, so all the tools that are normally taken for granted become cool and new again.

The left tip ribs took about 1/4 of the time compared to the right wing, and I can only imagine how much faster the rear ribs will be.

Project Status:
Wings: 10h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~111.5 hours

New Years Eve: About four hours were spent on the right wing. The rear ribs were drilled into place, along with the root rib. The spar tip extension was drilled into place. The slat brackets were predrilled. We also bought a new work light and some extrusion for the slat placement template. I could not find any t=.125 plates at the Home Depot, so I bought some thinner plate that will just be layered.

Project Status:
Wings: 9h ( 1h, 1h, 0.5h, 2.5h, 4h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~110.5 hours