I started the right passenger wing skeleton, it seems the factory assembled wing spar has multiple rivets in locations which will need to be drilled out to install nose ribs and rear ribs. Maybe I am missing something or have the wrong spar?
Is this a common occurrence or am I just unlucky?

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Comment by Jonathan Porter on December 11, 2016 at 1:15pm

Take the drawing and measure the 'stations' for the ribs. Make a little black mark at each station dimension, and number them 1, 2, 3, 4, etc...

Then you may notice that you are looking for a station that is not there!  

The angles riveted on are supposed to be there!

Take your time, and it will all become clear!

Comment by Terrence "Dr. Terry" Hall on December 11, 2016 at 10:05am

Thanks for the insight and help.

Comment by Terrence "Dr. Terry" Hall on December 11, 2016 at 10:02am

My paranoid sleep deprived delusion is that someone played with this before and shipped it back to Zenith.

I had to pick up the rest of my components and they found this sitting on the shelf and forgot that someone had did a bunch of weird riveting before sending it back. The other possibility is that it was put together after the Zenith Christmas party but probably last year. I put some photos on my builder page.

Comment by Terrence "Dr. Terry" Hall on December 11, 2016 at 7:24am
I will try to post some photos in the blog. There are 11 nose ribs and 9 rear ribs required in spar. There are some vertical L doublers already riveted in the spaces in stn 1300,2434 and 3060. The web channels are riveted in place at stn 500 and 720 without nose ribs. Is this a set of spars that someone attempted then shipped back to Zenith?
Comment by Terrence "Dr. Terry" Hall on December 11, 2016 at 6:55am
The other spar for pilot side looks symmetrically identical with the rivets also installed.
Comment by Terrence "Dr. Terry" Hall on December 11, 2016 at 6:44am

I will share some pictures because the plans call for about nine sets of nose and rear ribs into the spar and there are vertical lines of rivets in the spar already. I will also have some coffee. I will not drill out the spar until I have sought divine or electronic media intervention. It is Sunday morn after all. Thanks.

Comment by Jonathan Porter on December 11, 2016 at 5:34am
As Jimmy says, take another look.... and perhaps post some pictures. It is unlikely that you have to drill out rivets, but if you are uncertain, DO NOT DRILL OUT before sharing pics and speaking to the factory! (OF all the Zenith planes we have built we have not had to drill out on the spars... BUT you never know!
Comment by Jimmy Young on December 11, 2016 at 5:23am

You should have matching pre-drilled holes in the spar where the ribs to cleco right up. There are no factory installed rivets that drill out. It might look different after a good night's sleep and a couple of cups of coffee.

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