Part 5: Installing the "Upgrade Package" to our Zodiac CH 601 XL: Riveting the Spar Extrusion Angle

After having drilled out the rivets, we now cut out the original Top Spar Cap Angle (6W3-6) 1680 mm. from the inboard end to replace it with the 1/8-inch extruded angle 6-ZU-1-1, taking care not to cut into the rear upper spar cap (we leave the front upper spar doubler (cap 6W3-2) and the rear upper spar cap (6W3-2) intact):

We position and clamp the new Extrusion Angle (6-ZU-1-1) next to the original Rear Upper Spar Cap (6W3-4):

The video clip below shows more detail on this - we had to trim the top rear rib corners slightly to clear the new Extrusion Angles. Here, Roger back-drills the original spar cap angle to the new Extrusion Angle and then clecos it back into the wing assembly for riveting:

Next, we rivet the spar assembly back together with the new Extrusion Angle:

The riveted assembly: On the left is the new Extrusion Angle, with the original Spar Top Cap Angle on the right:

Here's the video clip showing the installation of the Extrusion Angle:

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Comment by Debra and Patrick Nesbitt on November 14, 2009 at 10:21am
These blogs and videos are a huge PR achievement for Zenith. There should be no doubt in the XL commutiy where Zenith stands, with the XL builders and flyers. I for one am glad I choosed Zenith (701).

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