This Q&A is now closed and replaced with a new Q&A based on the latest upgrade drawings at http://zenithair.com/zodiac/xl/data/6-ZU-NOV24.pdf

To all 601XL and 650 builders and aircraft owners. If you have a specific question regarding the upgrade, post it here and I will consult with Chris Heintz so that we can give you the best possible answer. Please be specific about your questions.

When posting a question or replying to an existing comment, PLEASE add it to end of the last page.

Zenith Aircraft is upgrading its 601 XL, so a lot of questions are answered on the step-by-step Blog Posts on this main page.

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Replies to This Discussion

Mathieu, probably a stupid question, but when removing the center wing spar and forward uprights do we need to be concerned about the fuselage twisting, sagging or bulging? In the blog I did not see any additional support on or under the fuselage so I assume that the mono-coupe construction has enough strength to hold everything in position. Am I correct in this assumption? Also will the final drawings be available on-line?

Bob Pickens Troy, Mo.
Bob,
Yes, you can keep the aircraft on the gear when doing this. The aircraft will not bend or twist. Yes, we will post the final drawings on line for free.
Hi, Gang. I am putting out a thought/suggestion to help those that really need the upgrade kit right away. If you need the upgrade NOW (your built airplane is grounded, your partially built plane is ready for the upgrade parts, etc.) then order it up.

If you are like me and have waited to see how this washes out before beginning construction (or are already building but not yet to the point where you need the upgrade parts) then wait a few months to order so that the available kits will go to those that really need them right away.

As a fringe benefit, the delayed order people will benefit from whatever field installation experience wisdom accumulates. And, if the kit is modified after learning a few lessons, we would get the improved kit (if there is one) by waiting to order. Works for everyone.
Bob,
Good point. If you will not be flying anyways in the near future, no rush.
Mathieu

Will the upgrade kit include the bolts in place of the driven rivets for the main spar?? Or are we going to have both sent to us so we can decide as we go along??

Larry Whitlow
Larry,
The kit will include the solid rivets as they are preferred. If you will need the bolts, you will need to purchase them.
Steve,
The retrofit kit will include the 5/16" bolts. If you have 3/8" bolts, they are fine. However, people who have 5/16" should not open up to 3/8".
Mathieu

Since I have never driven a rivet that size and have no tools to do such, I'm pretty sure I don't want to learn on the wing spar. I'd rather use the bolts. So Two questions..

1 When you say rivets are preferred, is there a reason?? Do bolts have downside??

2.Can bolts be used in place of all of the large spar rivets we have to drill out, including the center section?

Larry
Larry,
Solid rivets are excellent fasteners as they fill the hole and by doing this, its better for fatigue etc. Also, solid rivets are significantly lighter.
Yes, you can replace all the solid rivets with bolts, but the bolts have to be installed properly. Preferable into a tight-fitting hole, and torqued close to the max. allowable torque value.
Will a proper size reamer be included with the kit so, at a minimum, the spar bolt holes through the added material will be sized correctly for the new bolts. Simple drilling can produce a hole that is too large for a standard size bolt?
Louis, at $352 USD, no tools are supplied in the upgrade kit.
Not to be obstructionist, but has anyone flown a 601 with the upgrade package installed? Do we know that this isn't causing a different problem?

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