Canadian Flag Blowing In The Wind Ron Leclerc Zenith CH701 Construction Log


Zenair CH701 STOL Aircraft...
CH701 STOL

Winnipeg

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Metric Converter

mm
ft
in

Note:
1 in = 25.4 mm
1 ft = 304.8 mm
1 ft = 12 in

 
 
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Flanging Dies used on the Wings & Fuselage of the 701!

When I decided to scratch build an aircraft I took a real good look at what tools and equipment I would be needed to complete such a project. The one area I really looked at was the flanging dies needed for strengthening the wing web, spar web and bulkheads where the holes would be cut out to reduce weight. I felt that with the help of some basic woodworking tools I should be able fashion something that would/should work... maybe!

 
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June 5, 2007
Flanging Dies... 3 sizes, 65mm, 95mm & 115mm made out of plywood and oak...

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June 5, 2007
Flanging Dies again 65mm, 95mm & 115mm made out of 3/4" plywood and oak...

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June 5, 2007
Rear Bulkhead of 701 made out of 0.032 aluminum with flanged 95mm hole. This was the first use of the die... I wanted to try it on the heaviest aluminum part requiring flanging in the 701. Took 3 blows of my 2lb dead blow hammer to make the flange...

 
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Part looks very good... wood is ok - AND IT WORKS! The rest of flanging to be done, is with 0.025 aluminum...

 

50mm Flanging Die For The 701 Elevator Spar!

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November 24,2008
50mm Flanging Die: This a round die... 3.25" diameter, limited by the width of the elevator spar... see the construction procedure below...

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November 24,2008
50mm Flanging Die: Completed... the same construction procedure is used to make the other larger dies. The only difference is the chamfer is 3/8" as opposed to 5/16" for the 50mm die...

 

Construction Procedures For The 50mm Flanging Die...

Male Die...

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November 22,2008
Male 50mm Die: There are 3 thicknesses of plywood here... the 5/16" piece is chamfered 45°on the router:
3/4" - 3.25" dia cap
1/2" - 2.00" dia
5/16" -2.625" dia

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November 22,2008
Male 50mm Die assembly parts, stacked and ready for finishing...

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November 22,2008
Male 50mm Die: Please Note, that the piece of 2.625" diameter 1/2" plywood is only needed to attach the 5/16" plywood, to form the 45° chamfer on the router, it is then discarded after use...

 
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November 22,2008
Male 50mm Die: Here is what the 1/2" form and 5/16" plywood looks like after chamfering on the router...

 
Female Die...

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November 22,2008
Female 50mm Die: There are 3 thicknesses of plywood used here: The 5/16" plywood is the piece that is chamfered 45° on the router:
3/4" 3.25" dia cap
1/2" 3.25" dia
5/16" 3.25" dia

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November 22,2008
Female 50mm Die: The 1/2" plywood and the 5/16" plywood have a the 2" hole cut out with the fly cutter and then glued together. Then the 45°chamfer is formed on the router.

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November 22,2008
Female 50mm Die: This shows the 3/4" plywood cap ready to be glued to the chamfered piece... and then it is ready for the final finishing. A 1/4" bolt will be glued in the existing hole... to use as a guide for the male die...

 

Miscellaneous Tools.

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Air Riveter Gun... With the modified nose pieces to be used with the Avex 120° countersunk rivets. The nose pieces had to heated with a propane torch as they were to hard to drill with a 3/8" drill bit to form the concave head as per Zenith recommendations...

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Power Air Tools...

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Misc. Tools

 
Adjustable Pushrod Tool
 
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November 3, 2012
Pushrod Length Adjustment Tool - Used when making up the new VW Type 4 engine pushrods. Made from a used stock VW Type 4 aluminum pushrod(270mm). A used pushrod is taken, and a piece about 3/4" long piece is cut out, and both ends tapped for a 1/4" bolt with two jam nuts added. The rocker adjusters are then adjusted to VW spec(0.006") and the adjustable pushrod is inserted and adjusted to to the required length.... and the new pushrods are all made to this length! This tool can be purchased for about $15... but is so easy to make if you have a used pushrod! On the left is a used aluminum pushrod before it is cut to length... the one on the right is the new adjustable pushrod, it's as simple as that!

 
Measurement Tools:
 
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January 12, 2013
Micrometers required for measurement of crankshaft journals... 1"- 2" and 2" - 3"

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January 12, 2013
Dial Indicator - used for measurement of the crankshaft end play, cam lift, pushrod length and deck height!

 

 
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