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ZODIAC CH 601Series Kit Aircraft

THE FOLLOWING IS A DRAFT MANUAL

This manual has been written and published strictly for informational purpose. It hasbeen prepared as a guide to facilitate the assembly of the ZODIAC CH 601 kit aircraft. Itis published to supplement (and not replace) the Zenair drawings and manuals. If adiscrepancy arises between this informational manual and the Drawings, the Drawingsalways take precedence.

All pictures, diagrams, drawings or graphs, are used for general identification only, andare not to be taken to represent technical drawings or replicas of exact parts. You shouldnot consider the educational material in the manual to be the practice of general aviationnor is it intended for this manual to be a complete account of sheet metal aircrafttechnology: It is limited to the scope of the ZODIAC CH 601 aircraft assemblyThis manual is not intended to replace, substitute for or supersede any technicalinformation contained in the ZODIAC CH 601 Drawings and Manuals by Chris Heintz,or other designer’s specifications.

Zenith Aircraft Company (ZAC) nor its authors guarantees the accuracy or completenessof any information published herein and neither ZAC nor its authors shall be responsiblefor any errors, omissions, or damages arising out of use of this information. This guide isprinted with the understanding that ZAC and its authors are supplying information but arenot attempting to render engineering or other professional services. If such services arerequired, the assistance of an appropriate professional should be sought.

Copyright, 1995-2001 Zenith Aircraft Company

© Zenith Aircraft Company : Mexico Memorial Airport, PO Box 650, Mexico, MO 65265 USA (573) 581-9000 FAX: 573-581-0011

Description:

STABILIZERZODIACCH 601

Drawing Rev.

(3/00) 60-0060-00

ZODIAC CH 601

6T1-66T1-7

6T1-4

6T1-5

6T1-3

6T1-1

6T2-2

6T2-4

6T2-1

6T2-66T2-3

6T1-2

Tip Rib

Fiberglass Tip

Rear

Front

ZENITH AIRCRAFT COMPANY Print Date: 10/24/01 ZODIAC CH 601

STABILIZER ASSEMBLY WORK REPORT

Step Drawing pageSequence Check Part number & Description Qty Reference

1 [ ] 6T2-3 Rear Spar attachment t=.040” 1 6T2, 6F15

2 [ ] 6T1-4 Rear Spar t=.025” 1 6T1, 6T2

3 [ ] 6T1-6 Upper Doubler t=.040” 1 6T1 HD

4 [ ] 6T1-7 Lower Doubler t=.040” 1 6T1 HD

6 [ ] 6T2-6 Shim t=.040” 1 6T2

8 [ ] 6T1-3 Front Spar t=.025” l=2200 1 6T2, 6T3

8 [ ] 6T1-5 Front Spar Cap Doubler t=.040” 2 6T1, 6T2

11 [ ] 6T2-2 Attachment Doubler t=.025” 2 6T2

12 [ ] 6T2-1 Front Spar Attachment t=.063” 2 6T2

15 [ ] L ANGLE t=.025” l=4ft 1 6T2

16 [ ] 6T1-2 Center Ribs t=.016” (3R+3L) 6 6T1, 6T2

18 [ ] 6T1-1 Tip Ribs t=.025” (R+L) 2 6T1, 6T2

21 [ ] 6T2-4 Stabilizer Skin t=.016” dl=875, l=2245 1 6T2

Info [ ] FTT Fiberglass Tail tips 2

Info [ ] FTT Aluminum Reinforcement Rib 2

SIGNATURES: Builder _____________________________________ date

Inspector ____________________________________ date


REAR SPAR DOUBLERS T-35 The Rear Spar Attachment fits on the back side of the Rear Spar in order to bolt the Stabilizer tothe fuselage. Before installing, the side flanges are cut down from 22mm to 3mm on theoverlapping portion with the Rear Spar – this is to make clearance for the front bottom of theelevator during down deflection. The 20mm cutout from the centerline in the bottom of theRear Spar Attachment is to make room for the bottom elevator cable during up deflection. The Upper and Lower Doubler are Clecoed to the Rear Spar before positioning the Center Ribs.Later, when the Center Ribs are positioned they will overlap on top of the Doubler with a rivetthrough the middle of the overlap of the Rib flange with the Doubler.

1. LAYOUT the cutout on the Rear Spar Attachment 6T2-3: mark a 3mm offset line above theweb (the web is the flat area between the flanges). From the bottom, mark the corner at29mm and the top at 19mm, connect the slop line (bottom left on drawing 6T2 shows theside flange cutout reference from the top edge)

CORNER RELIEF HOLE: The edges of the corner relief holes are tangent to the sides ofthe cutout. Carefully center-punch the center of each ¼” hole above the 3mm line(approximately 32mm from the bottom). Drill the holes before cutting the side flange.

SAW: With the part clamped in a vise (protect the part from the sharp edges of the steel visejaws) use a hacksaw to carefully cut above the line. Be prepared to back off the pressure onthe saw when it cuts through the relief hole or it will cut and mark into the opposite side!File to the line to remove the saw marks for a smooth finish. For the middle opening, the12mm radius can be contoured with a large half round file instead of drilling a large 22mmhole.

2. Identify and label the top and front side of the Rear Spar 6T1-4: the top flange is 5 degreesclosed and points toward the rear. The bottom flange of the “Z” shaped spar points to thefront and is 5 degrees open (larger than 90degrees). Mark the aircraft center at 1100mm fromthe ends perpendicular to the bottom flange.

3. With the Rear Spar 6T1-4 on the workbench position the Upper Doubler 6T1-6 underneaththe top flange.

LAYOUT: Mark the rivet line on the Upper Doubler on the flange that overlaps on topof the spar web. The side flange is drilled later from the top through the skin. Also markthe aircraft center line at 610mm from the ends. The end holes are at 10mm from theends of the Doubler with the next two 20mm spacing. CLAMP: To center the Doubler on the Spar, super-impose the centerline of the Doublerwith the aircraft centerline of the Rear Spar. DRILL & CLECO: Drill & Cleco the three holes at each ends of the Doublers into theRear Spar web.

4. Cleco the Lower Doubler 6T1-7 to the bottom flange of the Rear Spar 6T1-4 CLAMP: Mark the rivet line, locate the aircraft center line, layout the end holes at10mm from the ends and the next two holes as 20mm spacing. Center the Doubler on theRear Spar clamp before drilling the three holes at each ends into the Rear Spar Web.

Description

ZODIACCH 601

Drawing Rev.

3/00

ZODIAC CH 601

T-36REAR SPAR ATTACHMENT

CORNER RELIEF H

OLE

1/4” HOLE TANGENT TO EDGE

20 mm

12 mm RADIUS

10 mm

19 mm

18 mm

CL

CL

6T2-3REAR SPAR ATTACHMENTt=.063”1 REQ.

6T1-4REAR SPARt=.025”dl=114, l=22001 REQ.

6T1-7LOWER DOUBLERt=.032”dl=34,l=12201 REQ.

6T1-6UPPER DOUBLERt=.032”dl=34, l=12201 REQ

CENTER UPPER AND LOWERDOUBLERS ON THE REARSPAR.

3 mm

TRIM 6T2-3

Right

Left

BACK SIDE

A5

A5 10 20 20

20 20 10

TOP

BOTTOM

Bottom

Top


REAR SPAR ATTACHMENT T-37 A Shim of the same thickness as the Upper Doubler fits underneath the Rear Spar Attachment. Finish drilling the Doublers to the Rear Spar by dividing the distance between the Center Ribsstations for a pitch of 40mm. The holes at the Rib stations are drilled later on the middle ofthe overlap of the Rib flange with the top and bottom Doublers.

5. CLAMP the Rear Spar Attachment 6T2-3 to overlap on top of the Upper Doubler 6T1-6.Slide the .040 Shim 6T2-6 in-between the Spar web and the Attachment.

CHECK:a) The top of the Rear Spar Attachment stops at the bend tangent line of the Upper

Doubler.b) The sides are at 90degrees to the bottom of the Rear Spar.c) The parts are centered on the aircraft center line (equal distance from the left or right

ends of the Spar).LAYOUT:a) Total of 25 A5 rivets into the Attachment (five rows of 5A5): the top and bottom

rows are through the Doublers with 3 rows into the Shim.b) 4 A5 rivet in one vertical column of rivets into the Shim and Spar on both sides of

Rear Spar Attachment. DRILL & CLECO: With #20

6. RIB POSITION TEMPLATE: The left and right sides of the Stabilizer are symmetrical,also the rivet pitch is the same in both the Top and Bottom Doublers. On a 4ft sheet metalstrip (approximately 30mm wide) or on a yard stick, layout the following rib stations at:160, 320 and 360mm . Clearly label the zero reference end from which the rib stations are set- the template is used by lining up the zero reference with the aircraft center line. Thistemplate will also be used to layout the rib stations on the Front Spar 6T1-3 and on theStabilizer Skin 6T2-4

7. LAYOUT: Use the RIB POSITION TEMPLATE with the zero reference on the aircraftcenterline to mark the ribs station lines on both Doublers (top and bottom right and leftsides). It may be easier to remove the Rear Spar Attachment to lay the zero end of thetemplate on the Rear Spar center line.

RIVET PITCH: Divide the distance between the rivet station for a pitch of 40mm.(using a 40mm pitch template). Also divide the distance between the Rear SparAttachment and the first Rib at station 160 for a pitch of 40mm. DRILL & CLECO: #20 drill bit. Before drilling, clamp or firmly pinch the Doubleragainst the Rear Spar flange. Wait to drill the holes at the Rib stations, they are drilledlater when the Ribs are positioned to center the hole on the middle of the Rib flange withthe overlap of the Doublers.


Description:

REAR SPAR ATTACHMENTZODIACCH 601

Drawing Rev.

1st Edition: 7-96

(3/00)T-38T-38

ZODIAC CH 601

6T2-6 HDSHIMt=.04060X781 REQ.

6T2-3

CENTER THE SHIM AND REARATTACHMENT ON THE SPAR.

6T2-3

6T2-6

6T1-46T1-6

6T1-7

6T2-6

6T1-4

6T1-6

20 A5 IN ATTACHMENT

160

320

360

5 A5 IN DOUBLER

4 A5 IN SHIM

CL

CL

CL

CL


FRONT SPAR DOUBLERS & ATTACHMENTS T-39 The Front Spar Cap Doublers are Clecoed against the inside web of the Front Spar

Note: Unlike the Rear Spar, the top and bottom flanges of the Front Spar are bent at the same angle.

The Front Spar Attachment is a 22mm wide angle reinforced by two Attachment Doublers. Aplywood template the width of the fuselage (219mm) is used to correctly space the two FrontSpar Attachment.

8. LAYOUT: The Front Spar Cap Doublers 6T1-5 are Clecoed inside the Front Spar 6T1-3

to the web, the side flanges are drilled later through the Stabilizer Skin 6T2-4. Mark therivet line in the middle flange as well as the aircraft centerline at 610 from the ends. Theend holes are at 10mm from the ends with the next two holes 20mm apart. CLAMP: Front Spar Cap Doublers to the side flange of the Front Spar. DRILL & CLECO: Drill & Cleco the six end holes with #20 in both Front Spar CapDoublers.

9. Carefully cut a plywood template 219mm wide with parallel sides at 90 degrees to the topedge.

LAYOUT: Draw the aircraft center line at 110mm down the middle of the plywoodblock..

10. CLAMP the 219mm template on the front side of the Front Spar by superimposing centerlines (the center line on the block over the aircraft center line on the Front Spar).

CHECK: Use a square to check that the ends of the Block are at 90 degrees with the spar.

11. Drill and Cleco the Attachment Doublers 6T2-2 against the sides of the template with 3 #20.REMINDER: the top and Bottom holes are also through the Cap Doublers on the reverseside.

12. Remove the block and clamp the Spar Attachment 6T2-1 to the Doubler 6T2-2 flange.a) Position the top and bottom holes through on the intersection of center lines with

Front Spar Cap Doublers.b) Add three #20 drilled holes evenly spaced between the two end holes.

13. FILE the top edge of the Doublers to avoid interference with the Stabilizer Skin 6T2-4(wedge shaped taking off approximately 3mm at the front).


Description:

FRONT SPAR ATTACHMENTZODIACCH 601

Drawing Rev.

1st Edition: 7-96

(3/00)T-40T-40

ZODIAC CH 601

CENTER THE FRONT DOUBLERSON THE FRONT SPAR

6T1-5FRONT SPAR CAP DOUBLERSl=1220t=.032” 6T1-3

FRONT SPARl=2200t=.025”1 REQ.

CL

FILE TO FITPROFILE

6T2-1FRONT SPARATTACHMENTl=105t=.063”2 REQ.

160

320

360

CL

MARK RIB POSITIONS ONFRONT SPAR

USING A PIECE OF WOOD, FIRSTPOSITION BOTH 6T2-2 DOUBLERS

6T2-2ATTACHMENT DOUBLERl=75t=.025”2 REQ.

219 mm

CL

CL

10 20 20

5 A53 A5

2 REQ.


FRONT & REAR SPAR T-41 Finish drilling with #20 the Front Spar Cap Doubler to the Spar web by dividing the distancebetween the rib stations with pitch 40.

14. CLECO: Use the rib position template to layout the rib stations. Divide the distance in-between the rib stations using a 40mm pitch template. The holes at the Rib stations aredrilled later through the rib flange.

SUGGESTION: Extend the rib station line into the radius of the doublers. Later whenthe ribs are positioned, the line will be visible past the edge of the rib flange and is usedto center the rib.

NOTE on the STABILIZER RIBS: The End Rib 6T1-1 is symmetrical about the longitudinalaxis, the Center Ribs 6T1-2 are also symmetrical about the longitudinal axis: the front flange is at90 degrees to the longitudinal axis. The front of the Rib is wider than the rear of the Rib: theFront Spar 6T1-3 is 84mm wide and the Rear Spar is 80mm wide. The front of the Rib can beidentified by the position of the tooling hole in the Rib web closest to the flange. A test is tohold the Center Ribs against the End Ribs back to back – hold the aft flange 18mm from the endof the full Rib as shown in the top left diagram on drawing 6T1 (the top flange of the Rear Zee isflush with the aft edge of the End Rib).Left and Right ribs are similar, the Ribs are positioned onthe skeleton with the flanges facing outboard.


Description:

ATTACHMENT DIMENSIONSZODIACCH 601

Drawing Rev.

7-96

(3/00)T-42T-42

ZODIAC CH601

CL

10 20 20

CL10 20 20

6T1-1

6T1-1

6T1-1

FRONT SPAR

REAR SPAR

6T1-1

6T1-1

6T1-1

PITCH 40 BETWEEN THE RIBS(Divide distance between intersectionholes and end holes)

BOTTOM SIDE

BOTTOM SIDE

A5 PITCH 40

A5 PITCH 40


RIBS T-43 First Cleco the Center Ribs between the Front and Rear Spar, then add the End Ribs. Theposition of the End Ribs will determine the position of the Stabilizer Skin: the End Ribs arepositioned flush with the aft edge of the top flange of the Rear Spar. Note: The bottom side of the Stabilizer Skin is shorter than the top side. - the bottom aft edgeof the skin is flush with the Spar web, the middle diagram on drawing 6T2 shows the Stabilizerskin and the Rear Spar, (also called the Rear “Z”!). Cut the two holes for the AttachmentDoublers in the bottom side of the Stabilizer Skin.

15. Prepare the Front and Rear Spar by installing the short length of L Angles at each end of

the spars to attach the End Ribs 6T1-1. LAYOUT: The L Angles are Riveted on the front side of the Spars with 2 A4 rivets intothe Spar web. NOTE: The L angle will rivet inside the End Rib – cut the length of the L angles to thewidth of the spar web (distance between the upper and lower bent tangent line).

16. Cleco the Center Ribs 6T1-2 one at a time first to the Front Spar then to the Rear Spar.MARK: the flange center line on the inside for the front and rear flange.

CENTER: Start with rib at station 160, center the Rib on the Spar between the top andbottom flange by holding the rib between your thumb and forefinger to feel the rib flush withthe edges. Clamp in place with one clamp on the Doubler. The rivet hole is on the splitmiddle of the overlap of the rib flange with the Doubler. Before drilling, use your finger topush the rib clear of the chuck; drill through the flange into the doubler and spar. Cleco anddrill the second hole. Remove and label the rib to repeat the procedure on the remainingRibs. Layout the rib stations on the Rear Spar using the rib position template to drill theribs.

RIVETS: 2A5 at the intersection with the Doublers.

2A4 in the Spar Web between the doublers, see drawing 6T2 bottom left diagram.

17. Cleco the Ribs to the Front and Rear Spars.NOTE: At rib station 360 the spars are drawn together by the thickness of the doublers

18. Position the End Ribs 6T1-1 flush with the aft edge of the top flange of the Rear Spar. CHECK: The distance from the Front Spar (web) to the front of the End Rib isapproximately 110mm. DRILL: Two holes #30 in each L Angles and the Rib web.

19. Deburr, apply the corrosion inhibitor (zinc chromate primer) if desired, and rivet the skeletontogether.


Description:

STABILIZER SKINZODIACCH 6O1

Drawing Rev.

1st Edition: 7-96

(9/97)T-44T-44

ZODIAC CH 601

6T1-2CENTER RIBSt=.016”3L & 3R

A4 PITCH 40BETWEEN RIBS

6T2-4STABILIZER SKINt=.016”1 REQ.

6T1-1END RIBSt=.025”2 REQ.

(L) ANGLE

2 X A4

WORKBENCH

bottom of skin

top of skin

2 x A4

Leading Edge Reference Line

2 x A4

CUT HOLES FOR THE SPAR ATTACHMENT

Leading Edge R

eferen

ce Line

PRE-DRILL SKIN

A4 Pitch 70

PRE-DRILL FOR RIBS

BOTTOM SIDE A5 PITCH 40

A5 PITCH 40

approx.110 mm.

CL


SKIN BOTTOM SIDE T-45 Fit the bottom side of the Stabilizer Skin first. Work with skeleton upside down with the skinoverhanging down over the side of the work bench. Reference the Skin along the aft edge of theSpar checking the center line of the bent leading edge radius against the Rib. Level the assemblyby blocking under the End Ribs and start drilling from the center out along the Rear Spar. Drillthe Ribs and the Front Spar starting at the center and moving out towards the ends. Rivet thebottom side before starting on the top side.

20. HANDLE THE SKIN WITH CARE: The best way to move the Skin is to grab hold of theSkin between your fingers along the rear edge (top side or bottom is immaterial). Keep your armswell separated to help support the Skin evenly. The same technique is used when two peoplemove the Skin; however one persons can handle the Stabilizer Skin very effectively.

21. Identify the bottom side of the formed Stabilizer Skin. Confirm by measuring the distancebetween the aft edge of the skin to the middle of the bent radius of the leading edge of theSkin against the same measure on the Rib (remember to measure from the spar web), thebottom side is shorter by approximately ¾”

CUTOUT for the front Attachment Doublers: Mark the aircraft center line and theposition of the cut-out to clear the two Front Spar Attachments 6T2-1 on the bottom side.Drill 3 corner relief holes (1/4”) and cut in-between or use a round rat tail file to connectthe holes!

22. Use the Rib positioning template to mark the rib center line on the skin, and mark the frontand rear spar center line on the skin. Layout the rivet pitch and drill pilot with #40 drill bit.

23. Position the Skin over the skeleton with the Attachment brackets through the cutouts. Ducttape the rear edge to the Spar web to hold the Skin flush with the aft edge of the Spar.

LEVEL: Slide 1x2” blocks under the End Ribs to remove any twist in the flexibleskeleton. CHECK: The position of the center line of the leading edge bend radius against the End Ribs. DRILL & CLECO: A4, start at the center and back drill into the Rear Spar alternatingbetween the left and right side working your way to the tips. Work your way up the Ribs and start drilling the Front Spar starting at the center workingtowards the tips. RIVET: With A4, rivet head on the .016 Skin.

24. Turn the assembly over and slide a 1”x2” board underneath the End Ribs to clear theAttachment brackets above the work bend.

STRAPPING: Run the strap underneath the workbench and over the Stabilizerassembly. Ratchet type straps are easy to adjust and can be set up ahead of time.


Description:

SKIN POSITIONINGZODIACCH 601

Drawing Rev.

1st Edition: 7-96

(3/00)T-46T-46

ZODIAC CH 601

A4 PITCH 35

BOTTOM SIDE

PUSH ON 2x4 SUPPORT TO FOLDTHE SKIN OVER THE STABILIZERAND RIBS

AFTER ATTACHING SKIN TO THESPARS, DRILL HOLES THROUGH

ALL THE RIBS

A4 PITCH 70

1" x 2"Wood Block


SKIN TOP SIDE T-47 Handle the Skin with care, use a 1”x2” 8 ft. long to help support the Skin when folding the topside of the Skin over the ribs. Slide another 1x2” underneath the straps just ahead of the FrontSpar to gently support the Skin. Slowly tighten the straps until the Skin lays flat.

25. Use straps to hold the Top side of the Skin on the Skeleton. HANDLING: To push the Skin down on the skeleton, take hold of an 8 foot 2”x4”along the sides, hold it up against the Skin and gently lower the Skin down. Partiallytighten the straps. Add another 1x2 just in front of the Front Spar for added support. 6straps is more than adequate! LEVEL: Block the front of the End Ribs to eliminate twist. Use a level to check bothends.

26. Mark the rivet lines for the front and rear Spar. Use the rib positioning Template to layoutthe position of the Ribs.

RIVETS +PITCH:a) A4 pitch 40 through the Front Spar.b) A4 pitch 60 through the Ribs.

c) Drill #40 Pilot holes.

27. Clamp the 6 ft (1830mm) Piano Hinge between the Skin and the Rear Spar, centered onaircraft center line.

RIVETS + PITCH: A4 through the Rear Spar and Piano Hinge. (Locate the end holes at10mm from the end of the Hinge). DRILL: #30 RIVET: A4

28. Add the Fiberglass tips inside the skin. PITCH: Draw a line at 10mm from the end of the Skin and duplicate the rivet pitch inthe End Rib by sighting across. DRILL & CLECO: #30 The Skin to the Fiberglass Tip.

29. Add the Tip Rib inside the rear ends of the Fiberglass Tips. DRILL + CLECOS: #30 Pitch 40

30. Rivet the tips with A4. 10/24/01: ZAC Engineering/601 manual/stab-TAIL1.doc

© Zenith Aircraft Company: Mexico Memorial Airport, PO Box 650, Mexico, MO 65265 USA (573) 581-9000 FAX: 573-581-0011

Description:

SKIN POSITIONINGZODIACCH 620

Drawing Rev.

3/00 T-48T-48

ZODIAC CH 601

USING STRAPS AND 1X2” BLOCKS SECURETHE SKIN TO THE STABILIZER SKELETON

INFORMATION SHEETTITLE STABILIZER Tail Tips Fiberglass Fairing (FTT)REFERENCE: 02/98 (3/00)PAGES: 1

The length of the Stabilizer Skin 6T2-4 at 2245mm is made longer than the skeleton, theoverhand is to rivet the Fiberglass Tips underneath the Stabilizer Skin.

Build and rivet the Stabilizer assembly by centering the skeleton in the middle of the Skin, splitthe overhand evenly between the left and right side. The Fiberglass Tips are positionedinbetween the top and bottom overhand of the Stabilizer Skin flush with the leading edge at thefront. Drill and Cleco a rivet line 10mm from the edge of the skin by duplicating the rivet patternof the End Rib. With the Tip Clecoed to the Skin position the aluminum FTT StabilizerFiberglass End Rib inside the rear portion of the Fiberglass Tips. Trace the position of the RearZee on the front of the Rib, remove the Tip to drill the Rib flush with the edge of the Tip. Drill theTip Rib to the End Rib 6T1-1 with two A4. Use A4 to rivet the Tip to the Skin.

ELEVATOR: The Elevator will fit in between the Fiberglass Tips, the trailing edge of theElevator is not flush with the end of the Fiberglass Tips.

SUGGESTION: Before installing, file the edge of the Fiberglass tips to remove any roughsurface.

COMMENT: The Fiberglass tips are symmetric, the top and bottom are the same, the left andright sides are the same. However there may be noticeable difference between the side edges,this is most noticeable when the edges are laid flat on the workbench: the overhand of the skinwill cover any irregularities.

TIP: Cut the bottom rear of the End Rib 6T1-1 on a diagonal between the bottom aft edge andthe top aft edge of the Stabilizer Skin, this is to avoid possible interference with full downElevator deflection.

NOTE: The front corners of the aluminum FTT Rib are cut back, this is the same part as theElevator Rib 6T3-1 before the front flange is bent.

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