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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 documenting and verifying the drawings and developing detailed step-by-step assembly instructions for builders and owners.
We've spoken with many builders over the last couple of days, and we want to thank you for your overwhelming support! We are working very hard to complete the Upgrade Package kit and to make it available to all so that it can be installed as soon as possible and at minimum inconvenience and cost. We'll be providing details on availability (how to order, etc.) later this week.
I plan to post updates here of our progress as we install this Upgrade Package to our demonstrator Zodiac XL to give builders and owners a good idea of the job ahead:
First thing first: Removal of the wings.
As Zodiac builders know, this is a straightforward process: Empty the fuel tanks, disconnect the controls, wires and lines, and remove the spar bolts:
Despite its age, our demonstrator Zodiac XL appears to be in great condition, with expected normal "wear and tear" to the cabin interior and exterior paint. We've taken hundreds of folks flying in this aircraft, and it's been around the country (several times!), and hundreds (if not thousands) have sat in it trying it on for size at shows around the country and at the factory.
Here's a brief video clip of the wing removal:
Our next step will be to drill out the rivets for the nose skin and top rear skin...
I'll be documenting the process here as we complete the Upgrade Package installation. Click here to view Part 2.
We've spoken with many builders over the last couple of days, and we want to thank you for your overwhelming support! We are working very hard to complete the Upgrade Package kit and to make it available to all so that it can be installed as soon as possible and at minimum inconvenience and cost. We'll be providing details on availability (how to order, etc.) later this week.
I plan to post updates here of our progress as we install this Upgrade Package to our demonstrator Zodiac XL to give builders and owners a good idea of the job ahead:
First thing first: Removal of the wings.
As Zodiac builders know, this is a straightforward process: Empty the fuel tanks, disconnect the controls, wires and lines, and remove the spar bolts:
Despite its age, our demonstrator Zodiac XL appears to be in great condition, with expected normal "wear and tear" to the cabin interior and exterior paint. We've taken hundreds of folks flying in this aircraft, and it's been around the country (several times!), and hundreds (if not thousands) have sat in it trying it on for size at shows around the country and at the factory.
Here's a brief video clip of the wing removal:
Our next step will be to drill out the rivets for the nose skin and top rear skin...
I'll be documenting the process here as we complete the Upgrade Package installation. Click here to view Part 2.
Tags: 601xl, ad, alert, amd, ch601xl, directive, faa, kit, package, safety
Comment
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Comment by Rick Morris on November 15, 2009 at 2:32am -
Hi Sebastien,
I have noticed that there is some flex in the top of Rear Frame Channel part No 6B5-2.
Do you think it might be a good idea to strengthen this Channel and perhaps tie the two rear wing attach points, part No 6B5-4, into it as well. Thank you for helping us, I'm sure we will end up with an even more beautiful aircraft.
Kind regards,
Rick Morris
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Comment by Dan Dempsey on November 13, 2009 at 7:43pm - Suggestion, put the aeleron hole stiffener inside the wing. That way the rear spar stiffener will fit without being bent. Also the hole stiffener would have a less acute angle to be bent.
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Comment by Jim Timm on November 13, 2009 at 4:35pm - I have close to 200 hours of very enjoyable flying in my airplane. Yes, the aileron control is a bit heavy and the pitch is responsive, but it isn't supposed to be an acrobatic airplane. Recognize it's flight characteristics and handle it accordingly. It's a very nice flying airplane the way it is. I do love flying it and I really hate the thought of tearing it apart and possibly screwing up what is now a very nice airplane. Having experience/knowledge of putting the wings on five 601XL airplanes, It will not be possible to add a .062 to the wing spar and get it to fit in the present center spar. Something will have to change, The tail dragger airplanes will have to have some special consideration on how to handle the forward fuselage skin reinforcement.
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Comment by Phill Barnes on November 13, 2009 at 4:28am -
Hi all
Sebastien asked me to send questions to his email and not to this blog but feel free to leave comments. Fare enough. Mathieu Heintz also has a Q&A forum here http://www.zenith.aero/forum/topics/building-hints-tips-and-tricks and is doing a pretty good job at answering questions thoroughly. Well done Heintz boys. Keep up the pics & vids. We all wanted a stronger plane, now we've got it. So long as we get all the infomation that we need or request, who can really complain.
Regards
Phill
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Comment by Richard Simmons on November 12, 2009 at 7:49am -
I am curious on the Aileron counter balance. Will this be here for the US and for the Hinge-less surfaces?
Are you putting these on the Demo plane?
Thanks for you efforts!
Rich Simmons
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Comment by Jonathan Starke on November 12, 2009 at 12:16am
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I see the demonstrator is the hinge-less aileron version, just like mine. Are you going to install hinges, and will the hinges be included in the ';upgrade-package', for us, as well as the balancing stuff required.
Thnx
Jonathan Starke
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Comment by Clarence K. Andrews on November 11, 2009 at 8:37pm
- Will it be necessary to remove the engine before removing the side skins? If so, would it be practicable to hold the engine's weight with a hoist and leave it attached, or maybe detaching from the longerons and holding the engine in place to avoid having to disconnect all the wiring from the engine?
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Comment by Mark Hubelbank on November 11, 2009 at 7:43pm - Given that the only "failure" documented in tests was the wing bolts and holes at the ultimate load (I know this is technically allowed) would this be a good time to also use a higher grade bolt and washer with higher torque? I can't see any down side but then I am not an aircraft designer.
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Comment by Phill Barnes on November 11, 2009 at 6:50pm
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Sebastien
How did the spar connection look? Any bent bolts or elongated holes or wear of any kind?
Phill
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Comment by Matt Archer on November 11, 2009 at 6:36pm -
Thanks for all the support. Look forward to seeing it progress and getting started. I am also planning on cleaning up some items and making some mods while I have it apart. Looking forward to starting.
Thanks for the continued support.
Cheers
Matt
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