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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Rudder Cable Outlet Fairing Tool!

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August 15, 2008
Rudder Cable Fairings... The two... 3/4" plywood blocks are clamped and a 1/2" hole is drilled at a about an 8 ° slope to the vertical, hinge is attached and you are ready to go. A half an hours work...

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August 15, 2008
80mm x 80mm Plywood Forming Blocks...

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August 15, 2008
Drill hole with 1/2" bit at about 8° from the vertical. Note that the hole is not in the center of the blocks... but offset about 3/8".

 
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August 15, 2008
Rudder Cable Fairings... forming block. two 80mm x 80mm 3/4" plywood blocks, hinge and 1/2" bolt.

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August 15, 2008

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August 15, 2008
Finished with a couple of coats of Varathane...

 

Fuel System Tools.

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November 18, 2008
AN 37 Degree Flaring Tool... Creates the proper angle for AN aircraft fuel fittings... includes flaring bar and yoke with center screw... fits tubing sizes 3/16", 1/4", 3/8", and 1/2" O.D...

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November 19, 2008
Pipe Tubing Bender 180 Deg Multi Size (1/4",5/16",3/8")...

 

New Tool!

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February 7, 2009
This is what they call a Vixen File... used in auto body work. Purchased from Princess Auto for $3.99. This tool is works good when you have to start deburring. Princess Auto calls it a Nib File - Coarse, its already mounted in the wood block, so there is nothing to do to put it to work...

 

Rivet Setting Tool - Made of Wood!

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July 18, 2009
Rivet setting Tool... ready for painting(blue)... Note the location of the hole for the steel rod... it is 3/4" from the front of the top beam... critical location. The reason for this is when you are building the front cabin sides there has to be enough room for the top beam's nose to fit inside of the horizontal lower parts of the cabin floor. Also the upper and lower pieces of nylon... add support to the steel rod and has a slight friction fit which allows the rod to be moved by hand without dropping onto the Rivet Setter Cup. The upper nylon piece is 1/2" thick and provides the friction needed to hold the rod in place and works great...

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July 18, 2009
Parts for the Rivet Setting Tool...
2 x 3 Top Beam - 22"
2 x 6 End Block(2 pcs screwed together) - 5"
2 x 8 Base - 26"
1/2" x 1" - 7" - 2024 Aluminum Bar
5/32 Rivet Squeezer Cupped... 3/16" shank. ACS #12-01562
1/2" Nylon - Upper Support
1/4" Nylon - Lower Support
1/2" x 12" 4130 Steel Rod

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July 18, 2009
1/2" x 1" - 7" long 2024 Aluminum Bar
5/32 Rivet Squeezer Cupped... 3/16" shank. ACS #12-01562
1/2" Nylon - Upper Support
1/4" Nylon - Lower Support
1/2" x 12" 4130 Steel Rod
The nylon pieces were an after thought to provide support for the rod and soon discovered that the slight friction fit prevented the rod from sliding down by itself, and allowed for hand movement only. Some commercial units have a spring mounted to the rod to prevent the rod from sliding onto the cup...

 
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July 18, 2009
Finished Rivet Setting Tool - ready for doing some riveting...

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July 18, 2009
Rivet setting Tool... This a steel unit similar to the one that appears on the www.ch701.com/ web site... Steel is ok, BUT we are dealing with soft aluminum and soft rivets... so wood works great and nothing fancy here, and does not mark up the aluminum...

 

VG's(Vortex Generators) Construction Tools!

Wings VG's - Flat Skin Leading Edge!

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November 27, 2009
Patterns used to develop the blank cutting board... and the forming boards. Made out of 3/4" fir plywood. the pattern is 60mm x 30mm by 35mm. The VG is approximately 15mm high at the top point...

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November 27, 2009
VG blank after cutting. 6061 T6 0,025 aluminum...

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November 27, 2009
VG blank ready to be formed into a part...

 
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November 27, 2009
VG Part nice and straight and ready to be deburred...

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November 27, 2009
A closer look at the newly formed VG Part...

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November 27, 2009
New VG part ready to be installed on wing...

 

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