I am sure there are a lot more 601, 701 and 750's out there that have experience this than Cruzer builders since the numbers are still low on builders at the moment. So I wanted to post this in the general area. I do also realize this is a new airfoil for Zenith so the problem may only by with the different shape of this leading edge. I assume that STOL has a much more "blunt" nose.

   There is about a 6mm small flange on the leading edge with eventually rolls into an 18mm flange for top/bottom of rib. I am having a hard time getting the metal to lay over with our crinkling up into a mess. Zenith press forms these parts into a die I assume, we are hammering them over wood. When scratch building do we need to remove some extra metal so there is less to bend over? Change fluting locations or add more? (photos attached).

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Your flanges at the leading edge are to long. I did mine with only a few mm and I was able to bend all around the leading edge without notches. See it here;

https://picasaweb.google.com/107779580539465100997/Wings#5189252923...

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