With the main wings done, we now focus on the aileron upgrades.

The aileron upgrades consist of three separate items: Aileron gussets (65W2-5 and 65W2-6) on the aileron ribs, L-angle stiffeners for the aileron trim servo, and finally, aileron mass balance. Above, the right aileron is shown. Below is the left aileron.
Our demonstrator Zodiac CH 601 XL airplane has the original "hingeless" aileron system - many customers have the hinged aileron option (6-PH-1). First we drill out the rivets...

...so that we can install the gussets (stiffeners): Note that for right side aileron we drill out just enough rivets to install the gussets, while we drill out all the top rivets for the left aileron to install the trim servo stiffeners.

The first gusset 65W2-6 is installed to the aileron rib#1. Note that these gussets were introduced last year as part of the CH 650 model updates:

Then we install the second gusset 65W2-5 on the aileron rib#2.

Gusset 65W2-5 on the aileron rib#2:

Next, we install the L-angle stiffeners on the aileron trim servo. This only applies if you have the aileron trim option (6-ATO-1) installed to your plane (and only to the side where the servo is located). Below is the left side aileron:

We trim standard L-angles to fit:

...and back drill the stiffeners in.

Next, we'll install the aileron mass balance:

Here's the video clip:


Roger Dubbert from the Zenith factory is scheduled to help out Gus Warren next weekend at the FlyWithGus.net Zodiac CH 601 XL "Upgrade Workshop" in Edgewater, Florida. Roger looks forward meeting with builders in Florida and going over many of the details of the new upgrades, and plans to have Upgrade Package kits available for pick-up by builders in Florida. For more information, contact Gus at 386-316-6324 or 505-363-9221