Replies to This Discussion

Permalink Reply by Robert E Pickens on November 19, 2009 at 9:10am

Mathieu, I have a question about the spar bolt tolerances. I had 2 bolt holes that became galled when taking the wing off and on to trim the skin. I slowly ran a .3123 reamer through them, they cleaned up nicely however these 2 bolts are snug, but not a tight fit. Do I have a problem?, what are the limits on these 12 fittings? If need be I can make corrections while doing the modifications. Thanks in advance, Bob Pickens, Troy, Mo.

Permalink Reply by Matt Heintz on November 19, 2009 at 11:58am

Bob,
On the 12 spar bolts, its hard to get an exact tolerance when we are talking a few thousands of an inch. What really makes it hard is when adding the tolerance of each bolt with that of the holes. So the easy answer is that you do want a snug bolt. Snug is when you can install the bolt without the need of a large hammer. Loose is when you can feel play when moving the bolt with your fingers and not recommended for these bolts. If a tight fit, you could damage the hole when forcing the bolt in (with a large hammer), so this is not recommended either.

You do need a calibrated torque wrench and you do need to follow the torque values in AC 43-13-1B table 7. For a 5/16" dia bolt with fine thread and using a MS20365 nut, the torque value is 100-140 inch-pounds. So torque the bolt close to the 140 inch-pound max. as this really clamps the spar caps together, adding strength to the joint.

Permalink Reply by Louis W. Ott on November 19, 2009 at 10:52pm

How about taper reaming the wing attach holes and using AN386 taper pins for the wing attach?

Permalink Reply by Matt Heintz on November 20, 2009 at 7:06am

AN386 taper pins are good in shear. However, we are also maximizing the bolts by adding strength when torquing them. This adds friction between the spar caps, so in a way, its like bonding the material together.

Permalink Reply by Don Walker on November 19, 2009 at 11:41am

On the 'Draft' upgrade drawings, there are a few references to an extrusion part "6UL2-4". My understanding of the drawing nomenclature would suggest that there is a drawing page titled '6-UL-2 and a part number 4'? I don't see this page anywhere. Am I missing something or is it a typo, as the reference seems to indicate the '6ZU2-4 Front Wing Uprights'?

Permalink Reply by Matt Heintz on November 20, 2009 at 7:07am

We will be issuing new drawings VERY shortly with significant changes. There will be 4 pages.

Permalink Reply by Robert E Pickens on November 20, 2009 at 7:46am

Mathieu, I carelessly put this back in an earlier post, sorry. I noticed in your response to Patrick Hoyt, you suggested that he retain the A6 rivets and not install additional rivets in-between them. Have you considered replacing the A5 rivets that most of us have in the spar cap with A6's. This would save a lot of drilling and although minimal a little weight. Consideration would also involve the availability of A6's. Just a thought,

Bob Pickens, Troy, Mo.

Permalink Reply by Harry O Watkins on November 20, 2009 at 12:00pm

My 601XL has two 12 gallon tanks in each wing, for a total of 48 gallons of fuel. This was the long range system when I bought my kit. I am wondering how this will affect the mods for the wing. Will the 1680 mm angle have to be increased in size?

Harry, Anacortes, WA.

Permalink Reply by Matt Heintz on November 20, 2009 at 2:51pm

The A6 rivets have a large head so the A5 rivets could look nicer. Either way, both are fine.

Permalink Reply by Matt Heintz on November 20, 2009 at 2:55pm

Steve,
Good question. In our static load test, the bolts did not fail even after exceeding ultimate. In regards to the accidents which I cannot say much due to my participation with the NTSB investigations, we have not noticed any bolt failures.

Permalink Reply by Matt Heintz on November 20, 2009 at 3:42pm

Steve,
You will be happy to see about 20% more material is added to the spar caps in the new upgrade kit.

Permalink Reply by JG Ginther on November 20, 2009 at 1:03pm

Resources for non-builders. As a second owner of a Zodiac with no ability to upgrade the plane myself, I am wondering what resources will be available to have the upgrades performed at a shop. Looking through the photos of the work, it looks to me like matters could be made much worse if the upgrades aren't done precisely. I would hate to tear apart a 400 hour, trouble-free, airplane and have a shoddy job done. Will Zenith recommend some shops for those of us that want someone else to do the work?

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