Part 24: Installing the "Upgrade Package" to our Zodiac CH 601 XL: Putting it all back together...

As you all know, we've been busy making the producing the parts of the Upgrade Package kit, and now we're also busy shipping them out to builders and owners!

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 Remember that the photo assembly guides are supplements to the actual drawings for the Upgrade Package.

Of course, we've also been busy finishing our demonstrator Zodiac XL aircraft:

Steve riveting the fuselage sides back together with the upgraded parts:

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!

Here's the video clip (added 12/18/09):

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Comment by Dan Ribordy on December 21, 2009 at 2:20pm
Are there any concerns with installing rivets on top of a painted surface or should the paint be removed before installing a rivet?
Comment by Hans van Riet on December 18, 2009 at 3:57pm

Would it be possibl to publish a list with the specific extra tools that are needed to install the upgrade package (what size wing nut clecos, how many etc. etc.).


Comment by Ted Taylor on December 18, 2009 at 2:18pm
I always thought you were suppose to fill old rivet holes with rivets, which is what I was planning to do. Covering them up doesn't make them go away. I guess we'll know more when we actually get the parts to play with.
Comment by Ted Taylor on December 18, 2009 at 10:50am
I've been viewing the upright doublers in past photos on the outside of the fuselage and supposed they were there for easy fitting. Now I see that they're actually attached to the outside. I'm thinking, when I actually get them in my hands, my inclination will be to try to re-engineering them to fit on the inside. Since you didn't, I'm anxious to see where the problem lies.
Comment by André van den Elsen on December 18, 2009 at 9:55am
Hello Sebastien,

I'm sorry but I can't find the foto Assembly Guides that accompany the Upgrade Package Kit.
Please can you give me a link?

Best regards,

André van den Elsen
The Netherlands
Comment by Richard Simmons on December 18, 2009 at 8:34am
I know this is silly but I actually smiled when i saw the first wing being installed to the fuselage.

Can't wait to hear when it is air born!

Comment by Ronaldo Santiago Silveira on December 18, 2009 at 5:15am
The part 6-ZU-3-5 can be installed inside the fuzelagem?

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