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All the Upgrade Package kit parts and hardware shown above can be shipped in the two cardboard containers: One box (18"x12"x6", 25 lbs.) for the smaller parts and all hardware and one 6-foot long 4-inch cardboard tube (about 16 lbs.) for the longer parts. These package are being shipped by UPS (for about $40 in the U.S.).
We also have prepared Upgrade Package kits for pick-up at the factory (pictured above).
We've also been occupied preparing the Photo Assembly Guides that accompany the Upgrade Package kit. You can download these Guides from the Builder resources section of Zenithair.com. Remember that the photo assembly guides are supplements to the actual drawings for the Upgrade Package.
Roger riveting the Bottom Skin Doubler (6-ZU-2-9) to the bottom of the fuselage:
The riveted fuselage side. (Note at the bottom we added a small doubler where we routed the fuel line through the fuselage wall. We did this since we had to move the fuel line hole forward to clear the front upright).
At this time, we also positioned and installed the Aileron Control Stop (6-ZU-4-1 & 2) at the rear torque tube bearing (behind the seat)
View from the rear of the Aileron Control Stop (6-ZU-4-1) clecoed to the Aileron Stop Support (6-ZU-4-2):
Since we had gained access to the rear fuselage (through the bottom access door), we took this opportunity to also install diagonal L-angle stiffeners in the rear fuselage (this is a standard feature of the CH 650 model):
Steve rivets the wing skins (we had waited to do this since it only takes a few minutes...)
With the upgrades completed to both the wings and the fuselage center section, we no rejoin them together:
Bolting the right wing to the spar center section:
The left wing top skin is now ready to be riveted and then the wing is ready to be bolted to the fuselage:
Bolting the left wing in place. Ah, it's looking like our beloved demo Zodiac XL once again!