Quick project update:

I have a bunch of photos to upload, but my home computer has been overheating, and it is low on the "fix list'.

Recently I got the tank channels into place, drilled and clecoed along with all the prep work to get the right wing ready for the top rear skin.

Project Status:
Wings: 45.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .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 )
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Total Done: ~147 hours

Wednesday I spend a few minutes making the jig for the fuel tank channel, and almost an hour cleaning up my workshop.

Monday some jerk broke into my Jeep at about 9:15AM, right before I normally leave for work, and stole my Garmin 496.

Sunday I finally flew a CH-701, albeit only for a little while and from the right seat. It gave me some renewed vigor to finish the project.

Project Status:
Wings: 44h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .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 )
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Total Done: ~145.5 hours

We spent about three hours on the wings today. The skin support for strut hole was fabricated and placed on the right wing. The left wing got the full treatment of the flaperon brackets, strut attachment and skin support being drilled into place.

More visitors came through the garage. This time a couple interested in building, but also on their way to visit a Czech 701 to potentially buy.

Sunday will hopefully bring high ceilings and actual time in the cockpit.


Project Status:
Wings: 43.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 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: ~145 hours

I spent about two hours measuring 7V4-4, cutting it, drilling the holes for the left and right wing, and then drilling the right piece to the right wing.

Some "L" angle was also cut and drilled that acts as a brace.

It has taken some time for me to realize this, but the drawing for a piece like 7V4-4 will be found on page 7-V-4. I was trying to determine the dimensions of the piece from the drawing of 7V4-4 that was on 7-V-5.

Right now my plan is to work only on the right wing for the moment since space is now at a premium. Once the right wing is finished, it will be hung on the wall and the left wing will be finished.

Project Status:
Wings: 40.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 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 )
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Total Done: ~143 hours

Already got a response!

Caleb got back to me with Zenith's uncanny quickness. The problem was me.

... I would suggest removing all the lines you have marked and starting over. Go to page 7-V-4 in your drawings, at the bottom is the part geometry and dimensions. I would start at the smaller end, draw a line at 16mm from the end, this is the line that the bolt hole is on. From the line you just made, mark a line at 115mm. Measuring from the edge that is 90 degrees to the larger end, measure along the second line you made and mark a point at 27mm. Then from the second line you made measure back towards the smaller end 15mm, make a point on the bottom. Draw a straight line between the bottom point and the point you made at 27mm. Now at the top of the part from the second line you made measure back towards the smaller end 41mm, make a point there and connect that point and the point at 27mm. All of the dimensions and part geometries are in your drawings.

I already used these ( better ) directions and the piece looks like that in the manual. Tonight I'll cut it.

Finally some time to work on the project....

We spent about two hours. The first hour and a half was spent figuring out the best way to get the flaperon brackets consistently placed. The end result was using some extrusion clamped to the top of the rib, then using some "L" angle to hold the bracket to the rib. The ends of the brackets were all made flush with the end of the rib.

I'm not sure how I got into this position in the first place. I drew out the rivet lines on the spar and channel, and the pre-drilled holes of the skin line up perfectly.

But as always, progress must be stopped. I believe that the 7V7-4 supplied with my wing kit may be mal-formed.

Basically making a mark 41mm from the 115mm mark to the right is past the piece. Making the 41mm mark to the left doesn't look right

The instructions in the manual are somewhat confusing, so I would be happy to find out I mis-interpreted them.


Project Status:
Wings: 38.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 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 )
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Total Done: ~141 hours