stol ch 801 final assembly - zenith aircraft companyfinal assembly section 1b - page 2 of 12 section...

STOLCH 801

Zenith Aircraft Companywww.zenithair.com

Revision 3.1(8/99)© 1999, Zenith Aircraft Co.

FINAL ASSEMBLYSECTION 1b - of 12

STOL CH 801FINAL ASSEMBLY

SECTION 1b(Continuation from Section 1a)

“JOINING THE FORWARD ANDREAR FUSELAGE ASSEMBLIES”

“Compass Check ” and “Helpful building tips ” - See Section 1a

STOLCH 801




Section 1: JOINING FORWARD AND REAR FUSELAGE ASSEMBLIESContinuation from Section 1a

file ff3-27 Photo fa1-16

A trial positioning of the cabin frame in the assembly is a good idea at thistime. A quick positioning will provide insight as to how everything will fittogether.


Pull the two fuselage sections apart. Place the heavy channel 8F5-4 inposition and layout the hole to be cut to clear the forward fuselagelongeron.

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Reposition the forward cabin assembly in the rear fuselage exactly asdone earlier. Re-cleco the 8F5-4 channels in place then drill the lowest-most hole in 8F5-4 and cleco. Drill only one in one side of the fuselage toallow further alignment of the two sections.


Temporarily clamp the cabin frame in position as shown in photo fa1-19through fa1-21.

This is not the finalposition of all parts sojust get things roughly inplace.

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Extend the fine string that was attached to the upper rudder hingeearlier, to a portable post positioned at the front of the aircraft. Set thelevel of the string so that it skims above the top of the rear fuselage topskin. Drop a plumb line from this line to the center of the firewall. Adjustthe post holding the string so that it is directly above the firewallcenterline. Note where the fine string crosses the centerline at theforward edge of the rear fuselage (photo fa1-6 and fa1-16). Loosen thecabin frame clamps and move the firewall and post left or right to bringthe string in alignment with the centerline on the rear fuselage.

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File ff3-22 Photo fa1-23

Check for sufficient edge distance in this area.


Re-check the level of the rear fuselage. See photo fa1-3. To adjust thecabin frame place a level on top of the assembly as shown. Also checklaterally on top of the forward tube.

First recheck the level ofthe aircraft at the rearfuselage.

See photo fa1-2.

Strive to keep the cabinframe level with the rearfuselage within 12mm.

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file ff3-35 Phot0 fa1-25

Position the cabin frame with it’s centerline directly under the stringrunning fore / aft.

File ff3-58 Photo fa1-26

Make a template to the drawing in photo fa1-26. This will be used toproperly space the wing attachment points, (the fore / aft positioning ofthe cabin frame)

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Use the template to accurately position the cabin frame in it’s fore / aftlocation. - Photos fa1-27 to fa1-29.


The top edge of thetemplate is placed flushwith the top of theattachment point.The board on top of thetemplate allows clampingto the cabin frame.

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The top edge of thetemplate is also flushwith the top of thebracket.


If necessary it is acceptable to insert a shim between the firewall and thecabin frame forward flange. To temporarily secure the cabin frame to thefirewall it is permissible to drill one 5/32 hole in the area directly above theintersection above the two tubes. Center the hole in this area and installa 5/32 cleco. Do not drill any other holes in the attachment flange at thistime.

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Position the forward legs of the cabin frame on the side skins. The legsmay be shortened 5mm maximum to assist in the leveling of the cabinframe.


Install the gusset #8F10-5 between the cabin frame and the cabin sideskin.

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Drill the holes in the cabin frame as indicated above in photos fa1-33 &34 on both sides of the aircraft.


Continued… Section 1c : JOINING FORWARD AND REAR FUSELAGE ASSEMBLIES

STOLCH 801




Revision List:

Revision Summary Revised By: Date:

3.0 Reformat SH 8/31/1999

stol ch 801 final assembly - zenith aircraft companyfinal assembly section 1b - page 2 of 12 section...

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