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I started today by re-putting the Z brackets on the spar, this time facing the correct direction of course. I figured I'd mess it up the first time just to add a little bit more frustration to these Z brackets...  Then it came time cleco together the fuel tanks. These things are a really tight fit and the metal is thicker than on the leading edge so they are a huge pain to put together but I got it done. One thing that really helped was I used an awl to line up the holes in the skin and ribs. I don't know how I would have gotten them together without the awl so I definitely recommend using one if you are making yourself some fuel tanks. Once they were together, I clecoed the baffle to tank and set the whole assembly in its place on the spar. Starting to look pretty serious.   The best thing about using the Checkoway method of Z brackets is the fit of the tank. Here is a shot of the gap in between the tank and outboard leading edge. It's pretty much non-existent as the tank fits just about perfectly perfectly. Now when I drill the baffle to the Z brackets, I guarantee this perfect fit!  Only one of the baffle/Z bracket attach points is visible at first so I match-drilled it with the 12" #30 bit.  Then I took off the leading edge and drilled the outboard baffle/Z bracket attach point.  Finally I took the tank off the spar and then put the baffle back on. The baffle without the tank on top exposes all the rest of the baffle/Z bracket attach points for drilling. Here they are drilled and clecoed. Definitely use a drill stop here so you don't drill into the spar after you break through the bracket.  Here is the result. Note the holes are slightly off center giving more room between the Z bracket web and the hole so it will be easier to pull the blind rivets that go there. This Checkoway method worked like a charm! After this, I did exactly the same thing with the left side. Even though they weren't too difficult, I'm really glad to be past these stupid Z brackets. I guess it's a mental block or something but I found myself constantly annoyed by these things. 
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| Thanks for visiting! | Last Update: 25 May 2012 |