Feb 24, 2024     Avionics and Lighting - (3 hours)       Category: Research

I attended the Aviation Conference in Puyallup Washington and contacted numerous venders regarding avionics, lighting, communication etc. I came away a bit disappointed that the cost of outfitting even a vfr aircraft was as expensive as I found. I was impressed with the panel design options available.

  Feb 23, 2024     Four Point Harness Option - (3 hours)       Category: Fuselage

I sent an email to Roger at Zenith regarding the Mount Channel rivet count and the Rear Gusset for the Mount Channel. I later called Zenith and learned Roger would be away for a week. Give this delay I completed layout and cutout of 75BRS1-3 Rear Gusset, using the old design shown in the plans. I used 6061T6 t= 0.050" and matched the rivet layout and rivet could according to build standards and incorporating existing rivet line. The shop built parts appear fine but I will verify with Roger when I speak with him.

In addition, I discovered I had received new Forward Angles 75F12-7 of t=0.032" when I received the Four Point Harness Option kit. I included a question to Roger about this.

  Feb 22, 2024     Four Point Harness Option - (3 hours)       Category: Fuselage

Reference Sheet C75-BRS-1 Four Point Haness - BRS.
Installation began with the drilling out of rivets on the Lateral 'L' under top skin to allow alignment of the Cockpit Harness Mount Channel (SD75F30-1). 'L' with be shortened and reinstalled at a later time.

I marked up the installation and clamped the parts in place. I noted that SD75F30-4 was sent in the kit instead of 75BRS1-3 Rear Gussets. The difference in the part changes the mount location against the Baggage Back and fails to align with the vertical rivet line under and slightly inside the position of Cockpit Harness Mount Channel. I will contact Zenith (Roger) about this change and options. I noted the plans illustration correctly showed the part 75BRS1-3.

A second question developed regarding placement of SD75F30-1, Cockpit... Mount Channel. I noted this earlier when plans reviewed. The Mount Channel rivet number does not reflect the number called for on the plans. Alignment however is not an issue.

  Feb 20, 2024     Four Point Harness Option - (3 hours)       Category: Fuselage

Plans review and general look at the installation of the Four Pint Seatbelt and design of cargo tie downs. The Plans appear straightforward although I did note that installation would be simpler when incorporated with the rear fuselage assembly. Additionally, the top rivet holes of the 750 STOL are not aligned with the kit component. (I spoke with Roger about this and he advised to double the rivets to account for the difference in number of rivets used for current model.)

Cargo tie downs can be incorporated during or post assembly. I've elected to not add at this time and wait until later.

  Feb 19, 2024     Landing Gear & Seat Base - (6 hours)       Category: Fuselage

Inside Landing Gear 'L' bracing final fitting completed. Part was made from 6061T6 t=0.025" material, primed and ready for rivet pull.

Left Seat Base 75F11-4 layout and cutout completed. Bends were made on using box brake. Left side seat base to side skin was modified to use an 'L' on the side skin and the Seat Base to rivet to the 'L' to ease fit and finish. Next step is establishing the matching rivet holes to Seat Channel and Seat Support.

  Feb 17, 2024     Seat Base - (1.5 hours)       Category: Fuselage

Right and left Seat Bases (75F11-4) inspected and left Seat Base requires replacing. I formed new left Seat Base from available stock on hand. Layout of the part was completed. The seat base on the left side covers the Gascolator and fuel line so an access hole will be incorporated. Cutout and bend will occur at later time. 6061T6 t=0.032" material used.

  Feb 16, 2024     Baggage Floor - (2.5 hours)       Category: Fuselage

Right side Baggage Floor (75F5-6) was replaced with shop fabricated part. This was due to the numerous rivet holes which had been drilled. New part was fitted and accept for the rivet holes and planned inspection plates the part is complete. Much improved over the original part. Materials (6061T6 t= 0.025") were from on hand stock.

  Feb 14, 2024     Airvent Intakes - (1.5 hours)       Category: Research

I researched designs of air vents for the cabin. I fund resources via EAA builders books on the NASA submerged ducts and how efficient they are and low noise. These also have the least amount of air obstruction. My intention is to install one on each side of the cabin but location is to be determined.

  Feb 13, 2024     Forward Angles - (4 hours)       Category: Fuselage

Installed forward angles and 'L' on right side. Final rivets pulled. The fit is much better and professional in appearance.

  Feb 12, 2024     Forward Angles - (5 hours)       Category: Fuselage

Continued work on forward angles. Fit middle and upper forward angles on the right and then deburred , primed and prepared for installation.

  Feb 09, 2024     Forward Angles - (4 hours)       Category: Fuselage

Installed left side forward angles (1.5 hrs). Removed 'L' on the right side (:30). Formed and fit new 'L' pieces on right side in prep to fit new forward angles (75F12-7). Matched fit bottom right forward angle (2).

  Feb 08, 2024     Forward Angles - (5 hours) Category: Fuselage

Formed third Forward Angle for the left side and cleaned deburred and primed mating surfaces of the 'L' and angles. Awaiting drying and then assembly.

  Feb 07, 2024     Forward Angles 75F12-7 - (5 hours)       Category: Fuselage

Drilled out rivets for the ill fitting forward angles which are to be replaced. I formed the underlying L and the fitted two of the t=0.025 parts (75F12-7) on the left side.

  Feb 02, 2024     Forward Angles 75F12-7 - (2.5 hours)       Category: Fuselage

My plans call for Forward Angles (75F12-7) to be made of 6061T6 t=0.025. Based on this I formed the six parts. I later found on the parts I had removed (removed because the edge profile was very poorly fitted) the parts were formed from t=0.032". I made a call to Roger at Zenith inquiring about this change and whether I should use 0.032 or stay with the t=0.025". On 1/7/2024 I spoke with Roger and he advised that his plans indicated t=0.025" and I would be ok to continue with this thickness.

My second question for Roger was regarding the Torque Tube Bearing Channel (75F4-5) which had excess rivet holes from the previous builder. I had emailed photo to Roger and he reviewed and advised to place doubler on off side of of rivet line and this will resolve any concern. This is also in accordance with the building standards.

  Jan 30, 2024     Elevator - (4 hours)       Category: Empennage

Fabrication of Elevator End Rib forms for part 75T3-1. MDF was used for the form. Practice part made to determine the depth of flutes for nose curve.

  Jan 29, 2024     Fluting Pliers - (1.5 hours)       Category: Tools

I need a set of fluting pliers so after reviewing a YouTube video on making some I did just that, i made a pair out of an older pair of vise grips. I MIG welded stainless steel rod on the jaws and tested. The pliers work reasonably well.

  Jan 28, 2024     Forward Angled (75F12-7) - (3 hours)       Category: Fuselage

I fully inspected the left and right forward angles and confirmed that all had multiple unnecessary holes drilled in them for rivets but there apparently had been an issue in assembly and the holes were not used. The extra holes were not limited to the Forward Angles but also the 'L' pieces which rivet direct to the skin. I shose to remove all of the forward angles and the 'L' pieces and replace.

Using 6061T6 t=0.025 I formed the new forward angles (75F12-7) for use in the change.

  Jan 28, 2024     Contacting Zenith - (30 hours)       Category: Research

I emailed Roger Dubbert regarding the Torque Tube Bearing Chanel and asked about options to address the multiple holes in the top of the Right Baggage Floor. I included a couple of photos for reference.

  Jan 26, 2024     Cabin Interior Area Assembly - (5 hours)       Category: Fuselage

I continued work in the cabin area and assembled baggage floor and last of center tunnel. All parts cleco'd in place and I identified the I need an angle at the right forward top edge of the control tunnel top. I did identify that the Torque Tube Bearing Channel had multiple holes on the top where the right baggege floor is riveted. The right baggage floor has corresponding holes. I have a concern about this and will contact Roger at Zenith to inquire.

  Jan 25, 2024     Elevator Assembly - (6.5 hours)       Category: Tail Feathers

I assembled the elevator and discovered hole misalignment on the end ribs (75T3-1). I examined the parts and switched them end for end and verified they had been correctly placed but I had an unusual tip upward of the skin at the tail end of the rib. I believe the issue is the parts were improperly drilled on initial assembly. I am going to create form blocks to make new rib ends and see if this will correct the issue.

I formed 75T3-4, Bent Strip, to replace the one installed which was not properly center on the spar.

I finished the bending of the Left control panel side (75F6-3) and set it in place for assembly. Using a block of wood as a backing I was able to drill the rivet holes aligning correctly with the baggage for and Control Tunnel Top (75F6-4).

  Jan 25, 2024     Elevator Assembly - (2.5 hours) Category: Research

Researched assembly of the Elevator. I watched the HomeBUILT.Help series related to this part for visual clarification of the assembly guide procedure.

  Jan 22, 2024     Safety Alert - December 2023 - (.5 hour) Category: Inspection

While on the Zenith 750 STOL forum (General) I read a reference to front landing gear safety upgrade issued in December 2023. I followed the link which took me to www.newplane.com where I found the four page notice. The upgrade states what modification must be made prior to the "next flight" so I will complete this upgrade during my build process

I should note that the Safety Alert upgrades I have found, such as the Fuselage Doubler and this notice, have been found by research and not by notice from the company. Many photos of aircraft I have seen have not had these changes made. I intend on taking care of these modifications during the build process which seems easier in the long run.

  Jan 20, 2024     Flaperon Control Arm (75F3-5) - (6 hours)       Category: Fuselage

Right side Flaperon Control Cover access hole was marked out and I jigged up a temporary vice to hold the part during the drilling of the 2 1/2" hole. Each flaperon control cover will have an access hole towards the top to open area for inspection and maintenance. The drilling was completed and I was pleased with the results. Both right and left Flaperon Control covers installed with cleco's and remaining baggage are panels set in place. These parts are cleco'd for reasons stated previously.

Both

  Jan 19, 2024     Assembly - (5 hours)       Category: Fuselage

I assembled bagged are and center tunnel with cleco's so I can move forward with replacing pilot seat area base and fit other panels forward of baggage area. The pilot seat base (75F11-4) was improperly installed with a poorly placed inspection panel by previous builder so it required replacement.

I installed new Fuselage Doubler on the left side with majority of rivets set. The new part is much nicer than the previous and eliminates issue of the gouge I caused. I also identified that I will need to replace (75F5-6). The current one has a messed up rivet line which has multiple rivet holes due to a misalignment so I will make a new one. I also have to replace the the left control tunnel side (75F6-3) I have cut out the part it only requires the aft angle to be made.

I won't be riveting baggage area panels until I choose locations of avionics. I believe inspect or access opening will need to be placed to facilitate avionics placement so I'll hold off riveting to avoid needing to drill them out.

  Jan 18, 2024     Fuselage Doubler Fabrication - (2 hours)       Category: Fuselage

Using 6061 T6 t=0.032 aluminum I fabricated a new left side fuselage doubler based on the previous which had been fitted to the plane. The fabrication went quickly and I was able to prime right away and allow to dry overnight. I also did some final trimming on a baggage area part.

  Jan 18, 2024     A & P Consultation - (.5 hour) Category: Inspection

A & P friend Jeff came by and looked over Fuselage Doublers and provided opinion on the left side doubler which I gouged. He provided a possible method to repair but said if I can make another I should. I will make another part instead of repair.

  Jan 17, 2024     Fuselage Doublers - (6 hours)       Category: Fuselage

I completed final fitting of Fuselage Doublers (75F10). All holes were drilled to A5 size as required. Additional holes were located in the field area of the parts per drawing. Rivet layout on plan was not very detailed so I positioned in accordance with drawing as best I could. I got right and left doublers positioned and all rivets pulled with exception of those necessary for internal panel mounting.

I begin began final fitting of internal baggage area panels which required some final trimming to properly position. During this effort I gouged the left side doubler to an extent that I may need to replace. I will have and A & P friend give his opinion.

  Jan 15, 2024     Fuselage Doublers - (3.5 hours)       Category: Fuselage

Today I finished cleaning burs on Fuselage Doublers (75F10) and completed drilling all holes, I cleaned and primed the mating surfaces. I them cleaned elevator spar, deburred holes and prepared for priming. When priming I've been using the small spray booth I made from cardboard. Exhaust is filtered before exiting garage.