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Part 19: Installing the "Upgrade Package" to our Zodiac CH 601 XL: Working on the Ailerons

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… Continue

Added by Sebastien Heintz on December 2, 2009 at 5:00pm — No Comments

Drilling Jig .

Today I uploaded some pictures of the drilling Jig that I have made. This tool should allow safe accurate removal of the AD5/6 solid rivets as required to incorporate the structural updates on the 601XL/650.

Added by Greg P Couttie on December 2, 2009 at 12:00pm — 3 Comments

Part 18: Installing the "Upgrade Package" to our Zodiac CH 601 XL: Working on the Second Wing

Now we're working on finishing the second (left) wing.

We debur and rivet the aileron bellcrank support channel and stiffeners, and the rear channel doubler...

And we bolt in the wing root doubler 6-ZU-1-2 and rivet the nose rib angles (6-ZU-1-3 and 6-ZU-1-5) in place...

...and we cleco and rivet the nose ribs in place. Note that in the photo we are… Continue

Added by Sebastien Heintz on December 1, 2009 at 11:30am — 4 Comments

Part 17: Installing the "Upgrade Package" to our Zodiac CH 601 XL: Finishing the First Wing

Now that we've installed all the upgrades to the first wing, we still need to finish a couple of items to the wing. With the wing skins clecoed back in place, we measure and mark off the 20 mm. hole placement for additional rivets into the inboard main wing spar (top & bottom):

We drill a hole between the existing holes...

Basically, we're doubling the number of rivets from the front and rear… Continue

Added by Sebastien Heintz on November 30, 2009 at 8:30pm — 2 Comments

Next Zenair Newsletter Issue: 601XL Upgrade videos

We are wrapping up final touches on the Nov/Dec issue of the Zenair Newsletter. The DVD included with this issue will feature videos from the Zenith factory demonstrating installation of the Upgrade Package on the 601XL demonstrator.



It is never too late to subscribe to the newsletter - each issue includes a DVD !

For information on subscribing, visit: subscribe online"…





Continue

Added by Zenair News on November 30, 2009 at 8:26pm — 3 Comments

Canadian Advance Ultralight CH 701 Registering

I am in the process of registering my CH 701 as a advance ultralight here in Canada. I heard back from Transport Canada today regarding my gross weight. I am trying to increase my gross weight from 960lbs to 1100lbs. Transport Canada will not allow this. I am aware that this has been done in the past. I have a letter from Chris Heintz dated Oct. 3, 1995 that the STOL CH701 may be operated at an increased gross weight. On Transport Canada's list of eligible ultralights allowed the CH 701 with… Continue

Added by Debra and Patrick Nesbitt on November 30, 2009 at 7:39pm — 1 Comment

Part 16: Installing the "Upgrade Package" to our Zodiac CH 601 XL: Installing the L-angle stiffeners to the top of the rear skin

We've made excellent progress over the past holiday weekend finalizing the drawings and verifying the parts. The wings are done and the center spar section is being verified.



As mentioned earlier, Gus Warren of FlyWithGus.net has announced that he will be hosting a Zodiac CH 601 XL "Upgrade Workshop" at his facility in Edgewater, Florida the second weekend in… Continue

Added by Sebastien Heintz on November 30, 2009 at 4:30pm — No Comments

Looking for things to do...

Well since I'm in the same boat as every else, waiting on parts, I went back to the final touches on wiring my panel



Here's my LED Caution and Warning system





And here's a close up. The Lexan cover is just taped into place to verify alignment of the legend





You can see a 3 side by side module on the wide shot over the Dynon. I designed and made a PCB to mount the… Continue

Added by Larry Whitlow on November 29, 2009 at 6:50pm — 3 Comments

Strut Fairings and covers

After some tweaking and twitching we have finished the strut fairings and the covers around the atachment points. Came out looking pretty good considering we didn't have a clue when we started. It did appear as though the factory bend on one of the fairings was slightly off and we needed to tweak it into place. Now if only I can get the cowling guy to get in gear and finish it!

We have had some great weather lately and I am missing it!

Added by Phillip Owens on November 28, 2009 at 9:27pm — 2 Comments

early kits with dual tanks each wing

so far i have stripped wing with ease the only problem was removing dual tanks due to plumbing. when installing, is there a specific order of assembly? to prevent additional do-overs your blogs and videos are EXCELLANT i would have more trepidation without them 4 1/2 hours to strip all but solid rivets

Added by Larry Webber on November 28, 2009 at 12:03pm — No Comments

Installing the "Upgrade Package" to our Zodiac CH 601 XL: Using an Angle Drill Attachment

As we've installed the "Upgrade Package" to our Zodiac CH 601 XL we've been using the same sheet-metal hand tools that are used in building and assembling an aircraft from a standard kit. One needed new tool is a right angle drill or drill attachment. We have used this extensively with the upgrade package to drill out rivets and to drill in the new parts.

While a… Continue

Added by Sebastien Heintz on November 27, 2009 at 3:58pm — 8 Comments

XL-Short field take off

What are you getting for short field take off and sod short field take off length of run?

Added by Frederick on November 27, 2009 at 8:13am — 2 Comments

6-ZU-3 doubling rivets

Looking at 6-ZU-3, I am a bit uncertain how far out to double rivets on the front and rear spars. Additionally, would it be a good idea to drill those new rivet holes prior to removing the skin so there would be better positioning and better clean up. Any thoughts?

Added by Karl Polifka on November 26, 2009 at 11:26am — No Comments

Zodiac CH 601 XL "Upgrade Workshop" in Edgewater, Florida

Gus Warren of FlyWithGus.net has announced that he will be hosting a Zodiac CH 601 XL "Upgrade Workshop" at his facility in Edgewater, Florida the second weekend in December. This is an excellent opportunity for East Coast Zodiac XL builders, owners, and pilots to learn about the new upgrades, and how to… Continue

Added by Zenith.Aero on November 25, 2009 at 5:30pm — 1 Comment

Part 15: Installing the "Upgrade Package" to our Zodiac CH 601 XL: Installing the Spar Wing Root Doubler (take two)

As shown previously (in Part 8), we had already installed a Wing Root Doubler (6-ZU-1-2) to the front side of the spar root, but as mentioned earlier (see my Part 13), a new Wing Root Doubler (6-ZU-1) replaces the previous doubler. This new doubler is cut… Continue

Added by Sebastien Heintz on November 25, 2009 at 5:30pm — 1 Comment

Part 14: Disassembling the Center Wing Spar Assembly and more...

As most of you know, we're now accepting orders for the Upgrade Package kit. We're not ready to ship the kits just yet, but we're getting everything organized so that we can ship as soon as the kit installation has been verified and documented, and that all the needed parts are in stock. We're prioritizing availability to first ship to those builders who are ready to install the Upgrade Package kit parts. We ask that those of you who are not ready yet to install the upgrade package to let us… Continue

Added by Sebastien Heintz on November 24, 2009 at 4:39pm — 4 Comments

Part 13: Removing the Wing Center Spar Section

Again, I want to thank Doug and Lori from Quality Sport Planes for organizing and hosting the free "Upgrade Workshop" this past weekend at their facility in Cloverdale, California (shown above). This was an excellent opportunity for Zodiac XL builders, owners, and pilots to learn about new upgrades, and how to install them. For more information, contact Quality Sport Planes at… Continue

Added by Sebastien Heintz on November 23, 2009 at 5:36pm — 3 Comments

Slider Canopy

Does anyone have knowledge of a slider canopy, with roll bar. used on a 601XL ??

Added by david a mcphee on November 21, 2009 at 9:20pm — No Comments

Slider Canopy

Does anyone have knowledge of a slider canopy, with roll bar. used on a 601XL ??

Added by david a mcphee on November 21, 2009 at 9:20pm — No Comments

Part 12: Installing the L-angle stiffeners to the rear bottom wing skins

Now we install L-angle stiffeners to the rear bottom wing skins:

This is an easy job with the top rear skin removed. We trim the L-angle piece to length, pre-drill it, and then drill and cleco it into the bottom rear skin:

We'll share the position measurements and exact details with the final drawings. The Upgrade drawings are nearly finalized (which will allow us to then release and… Continue

Added by Sebastien Heintz on November 20, 2009 at 4:30pm — 10 Comments

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