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 Larry Whitlow on November 14, 2009 at 10:44am
Well Done So Far!!! Glad For the documentation of the kit install.

Question The original notes said the extrusion angle doubler would be bolted on. You have obviously used solid rivets in attaching this piece. Is this how its gonna be done?? I have never driven a single solid rivet and have none of the tools required. Can these rivets be set with a squeezer?

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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