December 12, 2023

Riveted the flapperon arms. All rivets on the arm near the tank are set the blind side toward the tank to reduce a possible interference.

Since I did not set the rivets in the skin near the arms the riveting was smooth. I had not had to remove any rivets to make a room for the rivet tool.…

December 11, 2023

Leveled the wing. Used a laser guide to level. Much more convenient than a bubble or digital angle finder.

January 5, 2024

I made an error when drilling the bottom spar. While drilling the skin moved a bit. Because of this all holes in the spar look ugly.

I suspect it happend bacause I tried to use cleco #40. Instead I probably had to drill #40 and immadiately #30. I was not able to set cleco #40 firmly. Cleco #30 was set hard without any problem.

Because of some reasons it took me a very long time to contact Zenith and ask what options I have to fix my error.

It looks like I…

November 13, 2023

Started the pilot wing.
Removed the incorrect spar root angle. Started drilling and deburring the ribs.

November 12, 2023

Finished deburring the top skins. Reassembled the wing on clecoes. Put the wing on the storage rack.…

November 09, 2023

After a long time of doubts and experiments I am moving forward again.

I reinstalled the new spar root angle, nose root rib and the related parts.

Started removing the wing top skin to debur everything and prepare the wing for storage.…

November 1, 2023

Zenith sent me a new spar root angle. Matching it to the root top skin and the root nose rib was a difficult task.

I spent several days trying to match them. I have some version represented on the pictures.

I sent the photos to Zenith and will talk to them to decide it the solution is good enough to proceed or I have to invent something different.

I bent the angle several times. I am not sure it is still strong enough. May be I will ordere a new…

October 26, 2023

The new wider spar root angle does not fit the root top skin. The old one also does not fit.

The top of C75W4-2 Root Rear Rib is not flush with the spar top and with the Spar Root Angle. It corresponds to the drawings. The spar end height is 80mm and the Root Rear Rib front end height is 91mm.

Since the tops are not flush there is a gap between the Wing Root Top Skin and the Spar Root Angle.

The first two pictures show the spar and the Root Rear Rib are…

October 02, 2023

Making the C75W7-6 root top skin angles. The drawings has 2 pictures with them. On one picture they are straight. On the other picture they are curved.
Zenith says they should be curved.

September 30, 2023

Cut the C75W6-5 Wing Root Angle in two. Bent using a flute pliers.

Making the correct nose angle was the most difficult.

Made a 40x80 extender which goes toward the trailing edge.

Used a strap duplicator to drill holes in the root wing angle and not to enlarge the existing holes in the skin and the rib.…

September 28, 2023

The the C75W3-5 Wing Root Angle is incorrect. May be Zenith will send me a new part.

The kit has incorrect the spar root angle. The drawing says the flange should be 25mm wide. Mine is 20mm. The predrilled holes in the root skin are too close to the edge. Zenith is thinking how to fix it.…

September 26 2023.

Clecoed the top and the front skins of the right wing. Used ratcheted straps as the assembly manual says. Tried to do it by hand but failed.