Stol Ch 801 Rear Fuselage Assembly

STOL CH 801 REAR FUSELAGE ASSEMBLY

SECTION 1

CONTENTS

Parts list – two pages

SECTIONS #1a REAR BOTTOM SKIN ASSEMBLY #1b Continuation: REAR BOTTOM SKIN ASSEMBLY #2 LEFT AND RIGHT REAR FUSELAGE SIDE ASSEMBLY #3 REAR TOP SKIN ASSEMBLY #4a PART ONE: REAR FUSELAGE ASSEMBLY ‘JOINING THE REAR FUSELAGE SUB-ASSEMBLIES’ #4b Continuation: PART ONE: REAR FUSELAGE ASSEMBLY #5a PART TWO: REAR FUSELAGE ASSEMBLY ‘INSTALLING THE BAGGAGE AND CABIN AREA PANELS’ #5b Continuation: PART TWO: REAR FUSELAGE ASSEMBLY #5c Continuation: PART TWO: REAR FUSELAGE ASSEMBLY

SECTION 1: REAR BOTTOM SKIN ASSEMBLY

PART # PART NAME QTY SHIPPED INSTALLED 8F2-3A FUSELAGE BOTTOM SKIN 1 8F2-3B FUSELAGE REAR BOTTOM SKIN 1 8F3-1A BOTTOM REAR LONGERONS L + R STD Z L = 770 1 XXXXX L = 910 1 XXXXX L = 575 2 XXXXX STD L L = 450 1 XXXXX L = 615 1 XXXXX 8F2-4 REAR ACCESS COVER 1 8F2-5 REAR ACCESS COVER HIINGE 1 10-32 RIVNUT 12 XXXXX

SECTION 2: LEFT AND RIGHT REAR FUSELAGE SIDE ASSEMBLY

PART # PART NAME QTY SHIPPED INSTALLED 8F2-2A FUSELAGE FORWARD SIDE SKIN 1 8F2-2B FUSELAGE REAR SIDE SKIN 1 8F2-6 GUSSET 2 8F3-1B TOP REAR LONGERONS STD L L = 515 2 XXXXX L = 650 2 XXXXX L = 590 2 XXXXX L = 920 2 XXXXX L = 735 2 XXXXX L = 900 2 XXXXX L = 870 2 XXXXX L = 1190 2 XXXXX L = 1115 2 XXXXX

SECTION 3: REAR TOP SKIN ASSEMBLY

PART # PART NAME QTY SHIPPED INSTALLED F8F2-1 FUSELAGE TOP SKIN 2 8F3-3 GUSSET 2 8F16-12 SEAT BELT ATTACHMENT 1L + 1R STD L L = 450 1 XXXXX L = 615 1 XXXXX L = 775 1 XXXXX

…Continued

STOL Zenith Aircraft Company Revision 3.0 (9/99) REAR FUSELAGE ASSEMBLY CH 801 www.zenithair.com © 1999, Zenith Aircraft Co. SECTION 1a - Page 2 of 12 STOL CH 801 PARTS LIST: REAR FUSELAGE ASSEMBLY Page 2 of 2

SECTION 4: REAR FUSELAGE ASSEMBLY - PART ONE “JOINING THE REAR FUSELAGE SUB-ASSEMBLIES”

PART # PART NAME QTY SHIPPED INSTALLED REAR BOTTOM SKIN ASSEMBLY 1 XXXXX LEFT SIDE SKIN ASSEMBLY 1 XXXXX RIGHT SIDE SKIN ASSEMBLY 1 XXXXX REAR TOP SKIN ASSEMBLY 1 XXXXX 8F1-3 REAR H.T. FRAME 1 STD L L = 145 1 XXXXX 8F1-4 FORWARD H.T. FRAME 1 STD L L = 245 1 XXXXX 8F3-4 H.T. ATTACHMENT BRACKET 4 8F4-1 UPPER RUDDER HINGE PLATE 1 8F4-2A LOWER RUDDER HINGE PLATE 1 8F4-2B LOWER RUDDER HINGE PLATE 1

SECTION 5: REAR FUSELAGE ASSEMBLY - PART TWO “INSTALLING THE BAGGAGE AND CABIN AREA PANELS”

PART # PART NAME QTY SHIPPED INSTALLED 8F5-9 REAR SEAT UPRIGHT CHANNEL 2 8F5-10 TOP REAR BAGGAGE STIFFENER 1 8F11-8 REAR SEAT REAR CHANNEL 1 8F11-13 BAGGAGE BACK PANEL 1 8F11-14 BAGGAGE FRONT PANEL 1 8F11-15 BAGGAGE FLOOR 1 8F11-16 REAR SEAT BACK STIFFENER 3 8F11-7 REAR SEAT FORWARD CHANNEL 1 8F11-12 REAR SEAT BOTTOM STIFFENER 5 8F11-10 REAR SEAT BACK 1 8F11-9 REAR SEAT PANEL 1 8F5-3 TOP CHANNEL 1 8F5-4 SIDE CHANNEL 2 8F5-1 REAR WING ATTACHMENT 2 BRACKET

HARDWARE SUMMARY

PART # PART NAME QTY SHIPPED INSTALLED 10-32 NUTPLATES 12 STD L L = 1220 14

SECTION 1a

“REAR BOTTOM SKIN ASSEMBLY”

Compass Check

1. Cut skin to size. 2. Drill rivet holes for left and right longerons. 3. Fit stiffeners. 4. Cut access door and fit. 5. Rivet items together.

SECTION 1a

“REAR BOTTOM SKIN ASSEMBLY”

Helpful building tips:

1. As with the wings, elevator, etc., the positioning of parts i.e. left, right, top, bottom, up down, refer to the parts installed position when the completed aircraft is sitting at rest.

2. There are some areas on the skin which do not have predrilled rivet hole locations but appear as though the holes should be there. These areas are left un-drilled intentionally. Do not drill in these areas unless specifically instructed to do so.

3. Although it takes a little more time we recommend that all drilling be first done with a 3/32” drill bit.

file F300-18 Photo F1-1

STOL Zenith Aircraft Company Revision 3.0 (9/99) REAR FUSELAGE ASSEMBLY CH 801 www.zenithair.com © 1999, Zenith Aircraft Co. SECTION 1a - Page 6 of 12 The rear bottom skin consist of part #F8-2-3A & F8-2-3-B, the larger piece part A will require trimming. Part B is cut to size.

Part A & B have been predrilled as a matched set at the factory. Clecoing them together will automatically locate them correctly.

Note: The edges of skin F82-3A are not a straight file F-7 Photo F1-2 line.

Start by trimming the two skins to size. The photo indicates to cut to the inside but it’s a good idea to leave about ½ mm of the black line as a witness. Trim carefully as this will affect the final size of the aircraft and how some other parts fit.

file F-8 Photo F1-3

File the edge smooth.

file F-9 Photo F1-4

Cleco part A & B together. Assembly of the lower rear skins is done with bottom side up.

The lower longerons are part 8F3-1.

file F-10 Photo F1-5

Mark the centerlines along the length of the flange of the lower longeron. This is to provide a reference for later.

Mark the aft end of the longeron for trimming. The longeron is pre-bent at the factory with slight hook shape at the forward end. To ensure the correct longeron flange is trimmed place the left longeron on the table as depicted in the photo with the bend end to the right, pointing down. Mark the longeron as shown and trim. The right side longeron is a mirror image of the left. Mark and trim it also.

Photo depicts left side longeron.

The longeron was left untrimmed in this photo for purpose of clarity. All drilling should be with a 3/32" drill bit. The holes will be opened to the correct size later. The centerline is for reference only.

file F-12 Photo F1-7

Place the left longeron on the bench as shown above. The bent portion of the longeron hangs off the end of the bench to the right, pointing down. Place the rear bottom skin, part “B” in position with it’s rear edge at the left of the trim line. Position the skin flush with the edge of the longeron. Drill and cleco.

STOL Zenith Aircraft Company Revision 3.0 (9/99) REAR FUSELAGE ASSEMBLY CH 801 www.zenithair.com © 1999, Zenith Aircraft Co. SECTION 1a - Page 9 of 12 Locate the longeron flush with the edge of the skin. In this instance the centerline is for reference only.

file F-13 Photo F1-8

Drill one hole midway along the skin and cleco. Then one at either end and cleco. Attach part “A” to part “B” with four to five Clecos.

Depend on your centerline and the predrilled holes for positioning.

file F-14 Photo F1-9

The sides of the skin are not a straight line. Therefore continue to position the longeron as you drill. Cleco every second to third hole. Remove the longeron and repeat the process for the right side longeron. Check your work then drill the rest of the holes in the longerons.

Check photo F1-1 to determine the placement of stiffener “L’s” and “Z’s”. With both longerons removed slide a piece of 1x2 wood under the skin at the location of a stiffener rivet line. Slide a stiffener “L” between the board and skin. Align the centerline on the “L” with the predrilled holes, drill and cleco.

file F-16 Photo F1-11

Mark the “L” for trimming on both ends.

Continued… Section 1b: REAR BOTTOM SKIN ASSEMBLY

Revision Summary Revised By: Date:

3.0 Reformat SH 9/22/1999