Alexander Samoylovich's Blog (56)

Zenith 750 Cruzer, Clecoed the top skin

December 17, 2023

Clecoed the top skin. Preparing to drill the top spar.…

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Added by Alexander Samoylovich on October 2, 2024 at 9:39am — No Comments

Zenith 750 Cruzer,Installing Pitot tube

December 16, 2023

Drilled holes for the Pitot tube. Used a step drill.

Added angles to the wing top skin. I do not have a room to move the wing from the workbench quickly. I placed the top skin on sawhorses. I decided it would be better to have access to both sides of the skin when riveting. I set the skin vertically.…

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Added by Alexander Samoylovich on October 1, 2024 at 11:45am — No Comments

Zenith 750 Cruzer, Riveting the flapperon arms

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.…

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Added by Alexander Samoylovich on September 30, 2024 at 12:45pm — No Comments

Zenith 750 Cruzer, Rivetting the bottom skin

December 11, 2023

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

Added by Alexander Samoylovich on September 28, 2024 at 9:17pm — No Comments

Zenith 750 Cruzer, An error when drilled the bottom spar

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…

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Added by Alexander Samoylovich on September 27, 2024 at 10:45am — No Comments

Zenith 750 Cruzer, Started the pilot wing

November 13, 2023

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

Added by Alexander Samoylovich on September 26, 2024 at 9:59am — No Comments

Zenith 750 Cruzer, wing goes to storage

November 12, 2023

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

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Added by Alexander Samoylovich on September 25, 2024 at 3:20pm — No Comments

Zenith 750 Cruzer, Removing the wing top skin

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.…



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Added by Alexander Samoylovich on September 24, 2024 at 4:10pm — No Comments

Zenith 750 Cruzer, Matching the spar root angle

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…

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Added by Alexander Samoylovich on September 23, 2024 at 11:45am — No Comments

Zenith 750 Cruzer, A problem with the spar root angle

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…

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Added by Alexander Samoylovich on September 22, 2024 at 10:10am — No Comments

Zenith 750 Cruzer, Fabricating the root top skin angles

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.

Added by Alexander Samoylovich on September 16, 2024 at 1:46pm — No Comments

Zenith 750 Cruzer, Fabricating the root wing angle

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.…

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Added by Alexander Samoylovich on September 16, 2024 at 9:58am — No Comments

Zenith 750 Cruzer, Found Zenith errors

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.…

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Added by Alexander Samoylovich on September 14, 2024 at 6:26pm — No Comments

Zenith 750 Cruzer, Clecoed the top skins.

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.

Added by Alexander Samoylovich on September 13, 2024 at 9:49am — No Comments

Zenith 750 Cruzer, Preparing L angles to the top skin

September 24 2023

Preparing L angles to the top skin.

Clecoed the L angles to the top skin. Covered the skin and the L angles with cortec.

Levelled the right wing on the workbench. Preparing to work on the top skins.…

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Added by Alexander Samoylovich on December 19, 2023 at 6:13pm — 3 Comments

Zenith 750 Cruzer, riveted the flapperon arms

September 20 2023

Riveted the flapperon arms.

Made 2 mistakes.

Had to remove the rivets from the bottom skin near the flapperon arm doubler (3 places, 6 rivets together) to make the room for the riveter.

Riveted the first rib arm from inside to not interfere with the gas tank.…

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Added by Alexander Samoylovich on December 15, 2023 at 12:41pm — No Comments

Zenith 750 Cruzer, Clecoed the right wing skins

September 11 2023

Clecoed the right wing skins. Preparing to riveting.

Added by Alexander Samoylovich on December 6, 2023 at 9:27pm — No Comments

Zenith 750 Cruzer, Strut attaching point

September 03 2023

Drilled the spar.

Built the strut attaching point. Used a long flexible drill to drill wholes on the side.…



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Added by Alexander Samoylovich on November 23, 2023 at 9:12am — No Comments

Zenith 750 Cruzer, Clecoed the whole bottom side of the wing

September 01 2023

Clecoed the whole bottom side of the wing

Added by Alexander Samoylovich on November 21, 2023 at 8:08am — No Comments

Zenith 750 Cruzer, Level the wing skeleton

August 31 2023

Levelled the wing skeleton using shims.

Clecoed the wing outbound bottom skin.…



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Added by Alexander Samoylovich on November 18, 2023 at 1:10pm — No Comments

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