Mar 30, 2024     Seat Base (L) - (3 hours)       Category: Fuselage

I elected to replace the left Seat Base (75F11-4) due to the original have some issue with the access hole for reaching the Gascolator. Using 6061 T6 t=0.032" material I completed the majority of layout and cut part to size and bent the 90 degree angle on the inside. I then began locating the rivet lines but did not drill at this time. The lightening holes were located but not yet cut. I am considering options for accessing the Gascolator so until I decide my approach to access I will hold off on the lightening hole cuts.

  Mar 23, 2024     Seat Channel and Forward Angles - (3.5 hours)       Category: Fuselage

The new Forward Angles (75F12-7) on the right side were installed and like the left side they turned out to be a nicer fit and worth the effort in addition to upgrading to the new standard for thickness.

The Seat Channel (75F11-1) which spans from side to side was removed in preparation to replace. As previously noted the previous owner had extra holes drilled in the part which I did not care for so I ordered a new Seat Channel and will replace. To remove the part I had to notch the top and bottom and bend to allow clearance of the side and ease removal. The new part will be neatly notched top and bottom on the left side to allow flexing into position and then a doubler will be installed to provide the strength removed in the notch. The doubler will be 'L' and be secured to the face and the rivet line. Photos reflect the original Seat Channel with extra holes and the two photos showing the primed part installed with top and bottom doublers installed.

  Mar 22, 2024     Forward Angles - (2 hours)       Category: Fuselage

Right side Forward Angles (75F12-7) removed and the new (t=0.032") parts fitted for installation. These were deburred and underside primed.

  Mar 16, 2024     Forward Angles - (1 hour) Category: Fuselage

Bottom Forward Angle on left side installed.

  Mar 16, 2024     Forward Angles - (5 hours)       Category: Fuselage

I located replacement forward angles (75F12-7) from new parts from Zenith made of the t=0.32" material to replace the t=0.025" which I had installed. I removed the old Forward Angles and prepped the area and primed for the installation. I installed the top and middle Forward Angles and was pleased with the fitting along the outer skin.

Engine was rolled over on the engine stand, which I do every couple months to get the preservative oil on all surfaces regularly.

  Mar 15, 2024     Shop Cleaning / Research - (2 hours) Category: Workshop

Cleaning of shop and researching some painting options and considering paint as I go or build then paint. I decided on Priming critical areas / mating surfaces which will be exposed to more moisture or fuel and solvents.

  Mar 13, 2024     Rear Access Hole - (3 hours)       Category: Fuselage

I repaired the 'Z' angle located at the rear of of the bottom access hole in the rear fuselage. The installed 'Z' was slightly bent when working on the Four Point Harness installation. I used 'Z' as a doubler spanning the majority of the opening length. A4 rivet matched between parts. The result is more rigid.

  Mar 06, 2024     Four Point Harness - (3.25 hours)       Category: Fuselage

I assembled the left side of the Four Point Harness including rivets. Shoulder Harness bolts not installed at this time. I modified the 'L' stiffener on the roof of the cabin by making a bend in the angle which projects into the cabin. This created a channel which proved to be more rigid and part was formed from the original 'L'. I then cleaned the interior of debris from drilling and deburring as well as rivet stems.

  Mar 05, 2024     Four Point Harness - (2.5 hours)       Category: Fuselage

I assembled the right side of Four Point Harness. I immediately noticed how the fuselage roof stiffened considerably making the cabin I believe much more structurally sound,

  Mar 04, 2024     Four Point Harness - (1.5 hours)       Category: Fuselage

Final cleaning and deburring on Four Point Harness parts then primed all mating surfaces.

  Mar 03, 2024     Four Point HArness - (3.5 hours)       Category: Fuselage

Continued work fitting the left side Mount Channel, Rear Gusset and bracket to the fuselage. I found it necessary to remove the vertical 'L' on the back baggage panel to align the holes . Very difficult to access the rear of the back baggage panel through the access hole in the bottom of the fuselage. In the end I was able to locate and drill the required rivet holes but did manage to slightly bend the rear 'Z' on the access frame. I later straightened reinforced this cross piece with metal spanning over the slight bend, I believe moving the access panel 6 to 12" rearward would improve access in particular sense you cannot access anything rear of that panel to the tail. I did begin deburring the holes to be riveted in preparation for priming and assembly.

  Mar 02, 2024     Four Point Harness - (4.5 hours)       Category: Fuselage

7/16" hole was drilled for the seatbelt shoulder harness. I accomplished this by jigging the parts in the drill press and progressively drilled the hole small to large final size. This was completed for the right and left side and then I completed layout of the left side parts and drilled those rivet hole. The outside skin doubler was final drilled and rear gussets were placed with rivet location completed.

  Mar 01, 2024     Four Point Harness - (1.5 hours) Category: Fuselage

Deburring and edge prep of Four Point Harness, right side.

  Feb 29, 2024     Four Point Harness - (4 hours)       Category: Fuselage

I located and drilled all right side rivet holes in the Mount Channel (SD75F30-1). I prepped parts by deburring and red Scotchbrite in preparation for priming contact area and internal portion of the parts which will not be accessible after assembly.

  Feb 29, 2024     Four Point Harness - (.5 hour) Category: Research

Phone call with Roger at Zenith. Three topics discussed.
1) Forward Angles (75F12-7) - I discussed with Roger the difference in the plans call out of t=0.025" material and the delivered t=0.032" material. Roger said the new parts are t=0.032" but if the older t=0.025" are installed that is ok. Roger said the increase was likely due to the higher horsepower engines being installed by some builders. (*I have the newer parts on hand so will be taking out the t=0.025" and installing the new parts t=0.032").
2) Four Point Harness System - I explained the rear gusset issue including the plans illustration which incorporates the vertical rivet line and the the new rear gusset which does not. Roger said the new part is a change made in the newer models and is compatible with the BRS Chute system. Using supplied parts is fine or older style. (*I'm electing to fabricate the older design which incorporates the vertical rivet line.)
3) I asked about the rivet spacing on the Mount Channel SD75F30-1, Roger said I should double up on the rivets which will improve the strength and improve looks / symmetry. (* I will double up the rivets which is a win win.)

  Feb 27, 2024     Priming - (4 hours) Category: Fuselage

Prepped and hand primed mating surfaces of parts in baggage area and forward cabin. Hand brushed primer on mating surfaces.

  Feb 26, 2024     Seat Channel and Seat Base - (4 hours)       Category: Fuselage

During prior inspections I had developed a concern about the Seat Channel 75F11-1 having extra holes in close proximity to the factory routing holes. I looked at options to reinforce these areas and determined that the fix was not what I desired so I ordered a new Seat Channel from Zenith. I then realized that removing the existing Seat Channel will need a creative approach to install the new Seat Channel because the length prohibits installation without interference. To remove the existing Seat Channel I will need to notch the edges and bent the part.

The existing Left Seat Base (75F11-4(L)) was not finished well by prior owner so I intend to replace. I do intend to increase the access to the Gascolator through the lighting hole. I do not see any loss of strength in this size increase because the seat structure is improved through the adjustable seat slider and additional Seat Support 75F11-2. My plan for the Gascolator is to make a doubler to reinforce the thin skin metal around the Gascolator mounting location. I also thought about fuel line routing options considering my desire to install a fuel selector which has Right-Left-Both-Off. This in part due to experience with cross feed of fuel tanks in C15/152 and also desire to have a fuel shut off prior to the Gascolator.

  Feb 25, 2024     Four Point Harness - (3.5 hours)       Category: Fuselage

I began installation of the Four Point Harness (Seatbelt) components. During layout I found establishing the proper layout difficult due to the fuselage being fully assembled. Reaching through window openings and trying to measure was a challenge. I overcame this and was able to properly establish the Mount Channel locations. I removed the lateral 'L' to clear the path for the Mount Channels and located the front and rear gussets. I taped these in location and established some initial pilot rivet holes to hold everything in place while the remaining holes were located. I noted two items which I contacted Roger about. These two items were: 1) the Channel Mount rivet hole spacing was not Pitch 30 but closer to 40 so my question was should i go with the reduced number of rivets or increase? 2) The Rear Gusset marked with an SD75 part number does not align with the vertical rivet line of the rear baggage panel. Is this correct or should I be using a different part? Awaiting response from Roger.

  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.