The Bottom Skin
I cut the bottom skin to mandated dimensions using a knife and a straight
edge. Pretty simple...
Lower Rudder Hinge
The lower rudder horn is a quite complex assembly with two shims, the rear
frame L angle and the two hinges. I also checked the fit of the tie-down
ring (as seen on picture). To assure that the rudder is vertical, I will
drill the upper hinge (rudder and fuselage parts) together while validating
the position of the rudder.
Two frames on a piece of a skin
The two Horizontal Frames are assembled on the end skin. Prior to this,
I drilled the end skin with the main skin (step not shown).
Joggled H.T. frames I joggled the H.T. frames with the tool shown to assure a smooth fit of
the side skin with the lower longeron and the frames. This is achieved
with a piece of 0.063" aluminium with a notch. The H.T. frame's
flange is inserted in the notch and I squeeze the assembly with a vise.
The result is as shown on the picture.
594 + 20 - 12 = ?
According with the plan, the first stiffener on the bottom skin should be
positioned at 594mm from the edge of the overlap of the fuselage skin with the
center wing skin (ref. 6-F-1). At that location, the stiffener would
have been riveted exactly on the edge of the lower rear longeron and the
middle longeron (does not sounds right).
I changed its location so that it is installed with the last rivet of the
middle longeron (6F1-5). This change has not been validated with Zenith
Talking about the middle longeron The middle longeron is positioned to ensure that it fits inside the radius
of the bend of the Center Wing's rear Z.
This is the bottom of rear fuselage at a certain point (cross stiffener 6F1-6
not installed) prior to disassembly and priming.
Talking about 6F1-6... This piece has been a pain for me. A mistake
in positioning resulted in a bad cut of the part (too short). I made a
new one with a bending brake that could not properly form the second bend in
the part.... scrapped it again. I made the part a third time on another
bending brake (thanks to Claude Guilbault!) and now, it is excellent.