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 have some experience working with bucked (conventional) rivets. They require some special tools and skills. Your local A&P mechanic or an EAA chapter member may be able to help you and guide you.
To install the top spar extrusion angle reinforcement (6-ZU-1-1) we'll first need to drill out the top spar rivets 1680 mm. from the inboard end (the first 5.5 feet of the spar).
First, we drill out the rivet head:
(See the video clip below for a better view of this):
Then we knock-off the head:
Then, we hammer the punch to push the rivet out:
The spar is quite thick here and it takes time and effort to push the rivet out:
Using the pneumatic rivet hammer really quickens the process of pushing the rivets out. Note that we have not enlarged the holes in the process.
Here's a video clip of us drilling out the solid rivets:
Upgrade Package availability:
As many of you know, we're also really busy getting the Upgrade Package kit together: We're making excellent progress on this and we will be ready to announce availability soon. Check the Zenith website update page for details on obtaining your Upgrade Package.
This shows most of the Upgrade Package kit parts:
Over the last several days we have spoken to and have heard from many Zodiac XL builders, owners and pilots from around the world, and again, we need to thank you for your overwhelming support during this difficult period! 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.
I apologize if I have not yet responded to your email message or inquiry - I plan to as soon as I have the chance to. Please rest assured that your questions are not falling on deaf ears.
Custom instrument panels are now available directly from Zenith Aircraft Company exclusively for Zenith builders and owners. Pre-cut panel, power distribution panel, Approach Fast Stack harnesses, Dynon and Garmin avionics, and more.
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