Hi William,  Thanks for your comment on the fuel return. I am building with the partial kits and when I picked up my wing kit in 2012, the fuel return fittings were already welded in.

I was able to install the 1/4"ID fuel return hose in the nose skin radius, just ahead of the wing tank - pictures on my page. Best Regards,  Larry Zepp

You will have to have a return fuel line for each tank. To try and loop it some other way doesn't work, to many bubbles. Since there not hardly any room for a header tank, you will probably have to open up the leading edge skin on both wings to run return fuel lines.

Hi A friend of mine just called me and he found a punch that is small that will fit in a small inpact tool that will help remove the rivits. I will forward the e-mail when I receive the information so you can see if it is something that you could use. Right now I have to go to work at Cabela's so I can pay for all these improvments. Rog

William I had the batteries in the back but it was to tail heavy so I moved behind the right seat. I also reversed the landing gear so that the wheels are 6 inches forward. It takes some of the weight off the nose wheel. My empty weight is about 840 so with all the upgrades I am going to the light weight starter. I have both wings off and the rivits removed form the main spar. What a job. TO make it easier I took a dremel tool with a fiberglass reinforced cut off disc and cut off the mushroomed end of the rivit. Not the doomed head. This allowed me to determine were the exact center of the rivit was and to punch a small point to center the drill. Using an 1/8 in bit I drilled about 3/4 of the way through, then used a flat punch and a small impact tool to remove the rivet. Drilling off the head and then trying to get the exact center of the rivit proved very difficult. By drilling 3/4 through it releaved a lot of pressure on the rivet and they came out better. I am going to bolt the spar back together and not use rivits.
Rog.

Hi William The 0235 is from a 1961 Piper Colt. Zenith had an engine mount and cowling for it. The engine is a little heavy so I am going to change the starter to a light weight model and also replace the generator with an alternator. I installed an ADC remote oil filter which I am able to enclose in an air cooling shroud. The E-Mag ignition is great. So easy to install and time, just blow two times in the vacum line and it is timed. Fuel is pumped by two electic fuel pumps with only one needed because they pump plenty of fuel The engine burns about 5 gal an hour of auto fuel. It is the low compression engine. I have not been able to establish the cruise RPM and speed since I changed the pithch in the prop and restricted the air flow for colder weather. It warmed up and had to stay at 2200 rpms to keep the engine from over heating. It is equiped with straight stainless steel exhausts and sounds great. It idles at 650 to 700 rpms and starts in an instant. I am starting the upgrade and can not wait to get back to flying. I have flown it for 50 hours and it performs great. It does not seam to make any difference if I am in it alone or have it at gross. I do not even use the flaps at gross because it lands so nice.
Happy flying Roger

Congratulations and many more enjoyable flights in the future.

Ed

William
I had to place the battery in the tail also, I believe I weighed in at 840 I would have to check the books in the airctaft to be sure. You will love your first flight.

Mike

Yes, if the weather is favorable, I'm ready to get some time in the Zenith. Also, I got a bunch of work done on the tow-bars tonight. Should be finished soon. If you have any reservations about test flying your ship, I'm sure Boyce would be happy to make the initial flight to make sure all is well. Let me know and I'll get you connected. Lynn