Zodie

All cleaned up and starting on the right wing. It goes a lot faster now

Lessons Learned and Tips from the Left wing

Plan your work. The planning paper has really helped move through the process. The photo assembly guide is good at first. But ZAC kind expects you to use the plans more and more. Planning out your work prevents accidents.

Keep your assembly in the jig till you final rivet. If you have to take it out to do something. Put it back in when done. And always rivet in the jig.

Plan your wire penetrations early so you can cut the holes before the assembly

I ended up moving the holes lower on the left wing to keep the fuel low to the sender. So these are cut to match.

Debur as you go. I used a file for a while but a drill bit or the dogleg counter sink does a better job and doesn't scratch as much

Line up the rivet lines not the center of the rib. On the left wing I lined up the center line of the forward edge of the rib. The ribs are not perfectly square because of how the are formed. The important thing is to have the predrilled rivet holes in the skin line up. I carefully measured out the rivet lines from the plans and then lined up the ribs to the spar. On the top

And then with a mirror on the bottom. Then I tested the holes with a marker to see if I had an edge distance problem.

On this rib you can see the red marks from the hole test and see that it is not quite square. This really doesn't matter as long as you have edge distance. The important thing is that the rib flanges match up to the predrilled skin.

The right wing is really going a lot faster now.

I used Delta Cad to design a scaled down light based on ZAC's design and using the 50 mm lights from http://www.creativair.com/cva

Here are all of the parts cut and ready to prime

I also made a mold to bend the lense.

Here is everything clecoed together

Ok Quiz time. What is wrong with this picture?

Answer - The hole should be on the bottom not the top. Dang Nabit.

Measure twice. Cut once. Seems I wrote this before.

Here is my fix. I am putting a doubler and an angle to reinforce the hole. I will cut the correct hole later.

I am going to check with ZAC and see what they think.

The top skin is all drilled and ready to turn over and move the clecos to the inside.

Lower skin all drilled and nose skin mounted. Ready to disassemble, debur and prime

Here is the doubler installed.

Got a little help from my Son, Chris. We have the bottom skin riveted and have started on the top skin.

The Leading Edge skin bent and drilled

Leading Edge Light all cut and the lens test fit

Details of the Light mod

Another view

Filler hole is cut

Tank all tested and taped

Landing lights primed and assembled

Wired

Here you can see the keepers that I am using to hold the lens in place.

The keepers are joggled to keep the lens in place. I then mounted nut plates on the keepers. I will use the #10 screws to pull the keepers tight and this will keep the lens in place. The test fit went great.

Here the Leading Edge is riveted and the A5s are ready to pull.

All done. Gave a check of the light

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