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Part 9: Installing the "Upgrade Package" to our Zodiac CH 601 XL

Picking up where we left off in our last post, here we drill and bolt the cap spacer 6-ZU-1-6 centered between the original spar web 6W3-1 and the new wing root doubler 6-ZU-1-2:

Then we start deburring and riveting some of our Upgrade Package additions permanently into place, starting with the back of the wing, riveting the Top Rear Spar Angles and… Continue

Added by Sebastien Heintz on November 17, 2009 at 5:30pm — 1 Comment

Another Day At Can-Zac

Remember the CH750 kit owned by Angus Watt from Ottawa, the one I spent 8 days working on last month? Well, at the end of 4 weeks it looks like this... by the end of this day the wings and all flying surfaces are final fitted and it is once again dis-assembled and shipped to the paint shop today.
The CH801 (Yellow/Blue?White paint)in the back ground is a 4 seat model built for an outpost camp in Alberta.

Added by Bob McDonald on November 17, 2009 at 6:59am — 2 Comments

601/650 Upgrade Mods

I am in the process of building a CH 650. I have completed the rudder, horiz stab, and flaps, with the ailerons clecoed only. I have been holding off starting the wings until these mods are released. I have tried to be optimistic and positive about the 601/650 situation, and mainly just monitoring these sites. However, I still see some individuals on this site, and others, sticking their heads in the sand, bragging about flying being dangerous, riding motorcycles without helmets, and running… Continue

Added by Jim Snyder on November 16, 2009 at 6:37pm — 3 Comments

Part 8: Installing the "Upgrade Package" to our Zodiac CH 601 XL: Installing the Spar Wing Root Doubler (beta)

Now we install the Wing Root Doubler (6-ZU-1-2) to the front side of the spar root:

The Wing Root Doubler is a flanged piece that sits in front of the spar:

We decided to drill out the existing inboard noserib and replace it so that we could drill the Wing Root Doubler flange well into the noserib flange (the replacement noserib will be supplied as part of the Upgrade Package kit):…

Continue

Added by Sebastien Heintz on November 16, 2009 at 6:00pm — 3 Comments

New CH750 Video now available: FINISHING

HomebuiltHELP has now released the final volume for the airframe assembly in the series of Building your CH750: "FINISHING" This title covers mounting the HT, Wings, cables, controls, doors, fuel/wire routing, etc.

We are now working on a Jabiru 3300 engine installation video after filming with Mark Townsend at Can-zac aviation in Canada.

Added by Jon Croke on November 16, 2009 at 12:49am — 1 Comment

Part 7: Installing the "Upgrade Package" to our Zodiac CH 601 XL: Installing the Aileron Bellcrank Support Channel

As mentioned in my last post, I invite Zodiac XL builders and owners to check out and contribute to the "Zodiac XL Upgrade Package Q&A"

This will help answer many of your questions, and we ask that you ask your questions here (so that we may share the answers with many of you).



We also announced that Quality Sport Planes (in Cloverdale, California) that they will host a free "… Continue

Added by Sebastien Heintz on November 15, 2009 at 4:30pm — 2 Comments

SLSA

For those of you who own an AMD built XL that live in Idaho and/or Oregon, I can recommend a good mechanic.
Contact me for his name.

Mack P. Kreizenbeck
208-898-1494
aprazer@cableone.net

Added by Mack P. Kreizenbeck on November 15, 2009 at 2:00pm — No Comments

Part 6: Installing the "Upgrade Package" to our Zodiac CH 601 XL: Installing the Top Rear Spar Angle doubler

Next we install the Top Rear Spar Angle 6-ZU-1-3 reinforcement doubler inside the rear (spar) channel 6W7-2.

Below is a view of the angle inside the top rear channel (inboard, over the rear channel doubler 6-ZU-1-5 previously installed):

This angle doubler sits inside the top rear spar channel.

Steve first clamps… Continue

Added by Sebastien Heintz on November 14, 2009 at 3:30pm — 3 Comments

Part 5: Installing the "Upgrade Package" to our Zodiac CH 601 XL: Riveting the Spar Extrusion Angle

After having drilled out the rivets, we now cut out the original Top Spar Cap Angle (6W3-6) 1680 mm. from the inboard end to replace it with the 1/8-inch extruded angle 6-ZU-1-1, taking care not to cut into the rear upper spar cap (we leave the front upper spar doubler (cap 6W3-2) and the rear upper spar cap (6W3-2) intact):

We position and clamp the new Extrusion… Continue

Added by Sebastien Heintz on November 14, 2009 at 10:00am — 11 Comments

Opportunity Cost: Mods or BRS System

As I continue to meditate on the recommended grounding of my 601XL, I find myself more frequently browsing the ads in Barnstormer. One caught my eye today for a Ballistic Recovery Chute for $1200. My mind then wandered to a concept learned many years ago in an Economics class. The concept of opportunity cost - if I spend my money on mods, I will not be able to spend it on other things. Whatever I don't buy because of the mods represents an opportunity cost of the mods.



I still don't… Continue

Added by JG Ginther on November 13, 2009 at 2:30pm — 4 Comments

Part 4: Installing the "Upgrade Package" to our Zodiac CH 601 XL: Rear Channel Doubler

Next, we begin work on the rear channel doubler. This is a formed doubler that fits in the rear spar channel to beef up the rear spar attachment point.

The doubler is positioned on the inboard channel:

Steve drills and clecos the channel doubler:

Caleb and Roger drilling out the top main spar:

As we… Continue

Added by Sebastien Heintz on November 13, 2009 at 1:10pm — 3 Comments

Part 3: Installing the "Upgrade Package" to our Zodiac CH 601 XL: Drilling out the top inboard main wing spar

In our third installment, we drill now drill out the conventional bucked rivets of the top inboard main wing spar, starting where we left off with the top rear skin removed and the top of the nose skin opened:

Remember, I am posting this info to show you how we installed the Upgrade Package to our Zodiac CH 601 XL. This is not a set of instructions or a teaching aid. I only recommend that you attempt drilling out the solid rivets if you… Continue

Added by Sebastien Heintz on November 12, 2009 at 8:00pm — 9 Comments

My CH701 fuselage

Has anyone experienced this when joining the 701 rear fuselage to forward cabin? I built the rear fuselage and clecoed the seat back in place to the side vertical channels and uprights per the drawings. All dimensions and squareness checked out right on the money--not even off a milimeter. Same with the forward fuselage. When the seat back z-channel and 7F13-1 gussets were in place an riveted, the seat back no longer fit. In fact, at the z-channel I found the rivet holes through the side… Continue

Added by Don Herbel on November 12, 2009 at 6:44pm — 3 Comments

Part 2: Installing the "Upgrade Package" to our Zodiac CH 601 XL: Drilling our the top wing skin rivets

In part two of this installment, we drill out the Avex blind rivets in the top wing skins. (Click here for the first post in this series on updating our Zodiac XL demonstrator per AMD's Safety Alert / Directive).



See the video clip at the bottom of this post for a good view of how we drilled out the blind rivets.



Removal of the wings and drilling… Continue

Added by Sebastien Heintz on November 11, 2009 at 9:30pm — 3 Comments

Update kit

I am ready to start with the update kit.

When the FAA came around to do the final inspection for its airworthyness, the inspector for the FSDO gave me a copy of the NTSB article about the accidents. I had just come back from Sun and Fun where everyone was dissing my airplane. I was nervous enough that I didn't trust it.

I got so nervous about the safety of my little airplane that I have not flown it very much. I have been waiting to have the other shoe fall.

It has fallen, and I… Continue

Added by William Campbell on November 11, 2009 at 1:03pm — No Comments

Installing the "Upgrade Package" to our Zodiac CH 601 XL

Since the FAA's Special Airworthiness Information Bulletin (SAIB) and AMD's Safety Alert / Directive were issued on Saturday, November 7, 2009, we've begun the job of updating our Zodiac XL demonstrator per Zenair Upgrade drawings. As the kit factory, we want to have this done as soon as possible while also… Continue

Added by Sebastien Heintz on November 11, 2009 at 10:30am — 15 Comments

Cash for Clunkers: What is my Zodiac Worth?

Unlike many of you, I didn't build my Zodiac. It was built in a factory in the Czech Republic and I wouldn't have it any other way. I have the bent bicycle wheel that I attempted to straighten and the cable tv box I blew up with a little handy homeowner outlet I installed. No one wants me building or fixing an airplane. So I read the letter and learn there is going to be a tidy little "kit" to install and exorcise the demon in the machine. A kit sure sounds pretty easy. I then turn to the… Continue

Added by JG Ginther on November 9, 2009 at 10:43am — 7 Comments

The Zodiac Solution: Training Wheels on a Motorcycle

I flew my Zodiac three hours Saturday enjoying a breezy fall morning following the ridge line of the Shenendoah. The plain flew beautifully, hands-off for the most part, and passed its four hundredth hour of flight (70 with me at the helm). Little did I know that it might be my last flight for a while. As I was dancing in the clouds, others were buy putting the finishing touches on their effort to ensure my "safety." The NTSB, FAA, Zenith, The Associations and several foreign bodies had… Continue

Added by JG Ginther on November 9, 2009 at 10:04am — 8 Comments

Landing Gear indicator proto-type

Hi, I am mocking up a design for a landing gear indicator for my amphib floats which I plan to switch over from pneumatic to electric linear actuators. The indicator will incorporate 3 led bar graphs that will show the current gear position using the feedback resistors incorporated into the linear actuators. This unit will fit into a standard 2.25 inch hole.



I would be interested in feedback and ideas since I am in the early design stage.



Here is a concept diagram of the… Continue

Added by John Ellis on November 4, 2009 at 5:02pm — 7 Comments

Engine issues

Just wanted to add a note about what's happening with my airplane. On my last flight I decided to ground my airplane because of the engine using too much oil and fouling the # 4 cylinder. I pulled the engine off and brought it home to work on.



This past week I was able to finally get time to get it apart. The # 4 oil ring was missing about 1/3 of it, other wise engine is in good but worn out shape. As far repairs, looks like I can get all new bearing, rings and gaskets and be good… Continue

Added by Glenn Johnson on November 1, 2009 at 6:47am — 4 Comments

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