Upper Forward Wing Strut - Zenith Aircraft Builders and Flyers2024-03-19T01:03:31Zhttps://zenith.aero/forum/topics/upper-forward-wing-strut?commentId=2606393%3AComment%3A628643&feed=yes&xn_auth=noYou guys left me in the dust…tag:zenith.aero,2018-05-22:2606393:Comment:6290012018-05-22T22:13:48.035ZLoren Warnerhttps://zenith.aero/profile/LorenWarner
<p>You guys left me in the dust a long time ago, following the rudder build.</p>
<p>You guys left me in the dust a long time ago, following the rudder build.</p> Actually, I stole the idea fr…tag:zenith.aero,2018-05-22:2606393:Comment:6287802018-05-22T16:59:00.908ZClint L Goschhttps://zenith.aero/profile/ClintLGosch
<p>Actually, I stole the idea from David. I've been trying to keep my workmanship standards on par with David's, John's, and Joe H's planes (along with a bunch of others on this forum). I figure if my plane turns out half as nice as their's I'll be happy. Keep up the good work!</p>
<p>Actually, I stole the idea from David. I've been trying to keep my workmanship standards on par with David's, John's, and Joe H's planes (along with a bunch of others on this forum). I figure if my plane turns out half as nice as their's I'll be happy. Keep up the good work!</p> Ok, so doing as Roger suggest…tag:zenith.aero,2018-05-22:2606393:Comment:6286952018-05-22T13:47:20.119ZLoren Warnerhttps://zenith.aero/profile/LorenWarner
<p>Ok, so doing as Roger suggests by replacing with a flush rivet and slightly notching the back side to fit the rivet should suffice, although not as clean as Clint's double flush rivet.</p>
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<p>Thank you guys for the information.</p>
<p>Ok, so doing as Roger suggests by replacing with a flush rivet and slightly notching the back side to fit the rivet should suffice, although not as clean as Clint's double flush rivet.</p>
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<p>Thank you guys for the information.</p> I agree with David. The rive…tag:zenith.aero,2018-05-22:2606393:Comment:6288692018-05-22T11:20:40.533ZJohn Austinhttps://zenith.aero/profile/JohnLAustin
<p>I agree with David. The rivet IS necessary and apparently acts as a stress relief. I recall a simplistic explanation that "stress flows to the path of least resistance, just like water, and the rivet controls where that stress flows."</p>
<p>On my build, I pretty much installed the rivet per plans. I had to <em>slightly</em> radius the fitting's edge to clear the rivet and it seemed to work OK ... or at least has worked OK for 500+ hrs! ;>)</p>
<p>John</p>
<p>N750A</p>
<p>I agree with David. The rivet IS necessary and apparently acts as a stress relief. I recall a simplistic explanation that "stress flows to the path of least resistance, just like water, and the rivet controls where that stress flows."</p>
<p>On my build, I pretty much installed the rivet per plans. I had to <em>slightly</em> radius the fitting's edge to clear the rivet and it seemed to work OK ... or at least has worked OK for 500+ hrs! ;>)</p>
<p>John</p>
<p>N750A</p> David, this may be a long kno…tag:zenith.aero,2018-05-22:2606393:Comment:6289592018-05-22T04:38:52.573ZLoren Warnerhttps://zenith.aero/profile/LorenWarner
<p>David, this may be a long known problem to some Zenith builders, but it completely escaped me. Our 750 STOL is the latest version, and it's incredible that the builders guide and plans continue to require a rivet that we later need to replace. </p>
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<p>I just got email from Roger suggesting we "replace with a countersunk flush rivet and notch the backside of the strut fitting."</p>
<p>David, this may be a long known problem to some Zenith builders, but it completely escaped me. Our 750 STOL is the latest version, and it's incredible that the builders guide and plans continue to require a rivet that we later need to replace. </p>
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<p>I just got email from Roger suggesting we "replace with a countersunk flush rivet and notch the backside of the strut fitting."</p> Loren, this is not a newly di…tag:zenith.aero,2018-05-22:2606393:Comment:6288572018-05-22T02:27:59.089ZDavid J. Beaulieuhttps://zenith.aero/profile/DavidJBeaulieu
Loren, this is not a newly discovered problem among the builders. The necessity of the rivet has been discussed previously. If I recall correctly, Caleb (aero engineer formerly associated with Zenith)was insistent that the rivet be installed. Seems it acted as some sort of stress relief?<br />
Anyway, Clint has the answer, do a double flush traditional bucked rivet. There is room for a bucking bar on the backside, but it does take a bit of practice to set the rivet. If you get most of it in there and…
Loren, this is not a newly discovered problem among the builders. The necessity of the rivet has been discussed previously. If I recall correctly, Caleb (aero engineer formerly associated with Zenith)was insistent that the rivet be installed. Seems it acted as some sort of stress relief?<br />
Anyway, Clint has the answer, do a double flush traditional bucked rivet. There is room for a bucking bar on the backside, but it does take a bit of practice to set the rivet. If you get most of it in there and set, it's just a matter of shaving or taking it down flush with a file or sander. There is plenty of material to countersink into. Understood, I look forward t…tag:zenith.aero,2018-05-22:2606393:Comment:6289552018-05-22T02:03:02.577ZClint L Goschhttps://zenith.aero/profile/ClintLGosch
<p>Understood, I look forward to hearing how other builders have approached this.</p>
<p>Just for reference, here is the setup I might use to perform the countersink for the top hole, not much clearance in that location, the pancake drill attachment is available at yardstore.com. I've also attached a picture of a practice piece I used to try out the double flush technique. First try was a complete failure, countersink was too deep. Second try was better. Still need more practice before I…</p>
<p>Understood, I look forward to hearing how other builders have approached this.</p>
<p>Just for reference, here is the setup I might use to perform the countersink for the top hole, not much clearance in that location, the pancake drill attachment is available at yardstore.com. I've also attached a picture of a practice piece I used to try out the double flush technique. First try was a complete failure, countersink was too deep. Second try was better. Still need more practice before I try it on the real part, if I decide to do it at all. </p>
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<p> </p> Thanks Clint,
I've never seen…tag:zenith.aero,2018-05-21:2606393:Comment:6288502018-05-21T22:42:52.068ZLoren Warnerhttps://zenith.aero/profile/LorenWarner
<p>Thanks Clint,</p>
<p>I've never seen a pancake drill or double flush rivets. Something to look into even if we don't use it. </p>
<p>I'm hoping someone who has been flying their aircraft for a long time, after performing one of the other options will chime in.</p>
<p>Thanks Clint,</p>
<p>I've never seen a pancake drill or double flush rivets. Something to look into even if we don't use it. </p>
<p>I'm hoping someone who has been flying their aircraft for a long time, after performing one of the other options will chime in.</p> Hi Loren, I have a fifth op…tag:zenith.aero,2018-05-21:2606393:Comment:6286432018-05-21T22:14:55.382ZClint L Goschhttps://zenith.aero/profile/ClintLGosch
<p>Hi Loren, I have a fifth option for you, countersink both sides and set a double flush rivet. A pancake drill with either a deburring bit or a very shallow counter sink bit should be able to countersink the top hole.</p>
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<p><a href="http://www.vansairforce.com/community/showthread.php?t=118615" target="_blank">http://www.vansairforce.com/community/showthread.php?t=118615</a></p>
<p>This website has a discussion that may (or may not) describe it better.</p>
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<p>For what it's…</p>
<p>Hi Loren, I have a fifth option for you, countersink both sides and set a double flush rivet. A pancake drill with either a deburring bit or a very shallow counter sink bit should be able to countersink the top hole.</p>
<p></p>
<p><a href="http://www.vansairforce.com/community/showthread.php?t=118615" target="_blank">http://www.vansairforce.com/community/showthread.php?t=118615</a></p>
<p>This website has a discussion that may (or may not) describe it better.</p>
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<p>For what it's worth, I'm considering not installing it. The bolt seems to be doing most of the work in this joint.</p>
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<p>You may get many different opinions on this, go with the one that makes the most sense to you.</p>
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<p>Hope this helps! Good luck!</p>
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