Part 7: Installing the "Upgrade Package" to our Zodiac CH 601 XL: Installing the Aileron Bellcrank Support Channel

As mentioned in my last post, I invite Zodiac XL builders and owners to check out and contribute to the "Zodiac XL Upgrade Package Q&A"
This will help answer many of your questions, and we ask that you ask your questions here (so that we may share the answers with many of you).

We also announced that Quality Sport Planes (in Cloverdale, California) that they will host a free "Upgrade Workshop" during the upcoming November 20-22 weekend. This is one more way for Zodiac XL builders, owners, and pilots to get assistance with the new upgrades required for their aircraft. For more information, contact Quality Sport Planes. RSVP to (707) 894-4084. Thanks Lori and Doug for hosting this workshop!

Now, back to installing the Zodiac CH 601 XL Upgrade Package:

Here, we install the Aileron Bellcrank Support Channel (6-ZU-3-1) inside the wing, following the drawing 6-ZU-3. The heavy-duty Aileron Bellcrank Support Channel replaces the original bellcrank support channel 6W6-10, so we first drilled out the original and then back-drilled the new Support Channel in place:

Next, we reassemble the aileron bellcrank assembly to the new Support Channel:

And now we position the four new L-angles as shown on drawing 6-ZU-3.

The L-angles, two on the top and two on the bottom, are drilled through the skins and connect to the next inbloard rear wing rib. This adds a lot of rigidity to the aileron bellcrank area.

(The top angles will be drilled into the top skin later).

Here's the video clip of us installing the aileron bellcrank support channel inside the wing (per drawing 6-ZU-3):

Next, we'll install the wing root doubler on the front side of the spar root.

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Comment by Sebastien Heintz on November 17, 2009 at 3:35pm
Rolfe: Please post your specific questions on the Zenair Q&A discussion board.
Comment by rolfe benson on November 17, 2009 at 1:37pm
I am familliar with the Zodiac that crashed on Nov 7th and it had long range tanks and wing lockers. Are these
modifications causing a weaker wing structure? Will aleron balance weights work with a skin hinge?
Rolfe Benson

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