Zenith Super Duty FUSELAGE! (Ep20)

Today I'm skipping ahead a little bit and starting on the aft fuselage. This is going to be a lot of work disassembling and assembling. Find out why!
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#SuperDuty #kitplane #zenithaircraft

[@novicereloader]

Two weeks is too long, man. I don't think you realize how many people are living vicariously through your channel.

[@gyrodeputyowl1711]

Great stuff. There is nothing wrong with doing it correctly! Taking pride is a great trait.

[@schwemdog1]

Mark, your attention to detail is contagious. I blame you for all the rounded edges and and lack of burrs on all the metal parts on my zenith build.

[@mwcar416]

Again I love your attention to detail. I agree with Bryan's comment about waiting two weeks, but I do realize you do work too. So I'm not being critical.

[@azzamaddas4437]

Good to have you back in the shop so our enjoyment and learning continue. I hope that the kit maker sees your videos and incorporate same diligence on deburring on their future kits to be delivered.

[@davidrobins4025]

Your attention to the details is a motivational factor for all builders to do it right. It requires lots of work, but is really worth all the time. I agree with the idea of not having the parts prebuilt - - unless that detail work is done. If the two triangular parts were in a display case, I'd choose your part every time.

[@garyc7517]

On the flapperon, what about putting string (or cord) through about 1/3 of the holes in that far edge, then a u nails in the 2x4 at the edge of the bench and tighten those cords up (rather than pushing with the 2x4) Gradually tighten the cords until you are close and can cleko the edge in place.

[@davejoynt6276]

Perfection is everything. Nice job.

[@01boian]

Totally agree with your piece beeing much better!

[@johngood3163]

Wow! We're sold on building the fuselage ourselves. We were going to go the quick build route, but we agree that the factory's finished product is not what we're looking for. It now saves us about $5k on the Cruzer build by not doing the quick build, and we'll have a better build in the end. Thank you for this great insight.

[@MRJSWORKSHOP]

As always very detail into your work and professional. This very educational to know about how the kits are build. I have work many years in production machine shops and Proto typing most of shop did complete demurring there are others shop that charge extra for the deburring because so time consuming. I personally don’t mind deburring.

[@LTVoyager]

Ratchet straps are your friend. 😁

[@alharaway608]

I was thinking the same thing. Seems like several strategically placed ratchet straps might help.

[@bobfindley6949]

@@alharaway608 that and maybe the use of that 2 by 4 as well. you should be able to control it fairly well.

[@simonbaxter8001]

Yep, same technique is used pulling the wing leading edge skins onto the ribs on the early Vans RV kits.

[@whathasxgottodowithit3919.]

Quality work, good job

[@edwardmullen1581]

Others haved used ratcheting straps in three or four places to do solo.

[@scottmiller4711]

Here is a recommendation regarding the wingtips (I did this with mine)...run a strip of thin aluminum along the inside of the wingtip mounting flange (I used both adhesive and rivets to hold it in place. This will give you more support and strength this allows you to sandwich the plastic between metal.

[@KitplaneEnthusiast]

That is what I was planning to do. I wasn't sure if anyone else has done this so I'm glad you did it and it works!

[@marchallairsoft]

Looks good the way you do Greets from Holland

[@johnburns9950]

I found gorilla tape worked to help hold the flaperon skins in place. I used it like a ratchet strap since i could pull and restick several times while bringing the skin closer to the lap joint. It also helped to pull it part way and leave it overnight.

[@smohan9271]

Good explanation

[@Know-Way]

Coming along. Excellent video. Seems like a $$ making opportunity for zenith. Offer a hole deburring service. They could just put a deburring bit in the CNC and run it again. It seems like the least fun part of the build. Some might pay extra to avoid it.

[@stevefeller4266]

Sheet metal screws? Are you worried they will strip out that plastic? Nut plate with a machine thread might be a better option? My 2 cents.

[@KitplaneEnthusiast]

This really wasn't the video to go into detail about the wingtip, but yes the plastic as it is would be too thin for screws. But there are many ways to add a backing to the tip to give it the thickness and strength for screws. I will show all that on a future video.

[@stevefeller4266]

@@KitplaneEnthusiast cool

[@electoplater]

i would have thought the plastic would need a clearence hole for the screw we will see when he screws it together,

[@dibyendu2roy404]

Very useful video. Thank you very much. 👍🇮🇳

[@artswanson5301]

Trust me on this. Use tinnerman nuts for the plastic. Sheet metal screws will wear out and damage the holes if they are raw.

[@Know-Way]

Tinnerman nuts. Ah, I didn't know what they were called. Thanks for the knowledge. I was thinking similarly, that the plastic may be a bit weak. My first thought was to epoxy a thicker piece of plastic banding inside the wingtip as a backer. Or, maybe a piece of aluminum banding/strap. He'd probably need far fewer screws too.

[@schwemdog1]

Also called u nuts. It's what my cherokee uses on the fiberglass wing tips. Definitely the way to go.

[@DrT_MD]

Any advice for a neophyte builder on where to learn tips and techniques like this? I’ve been thumbing through the aircraft spruce catalogue, and it’s hard to know what’s possible or under what circumstance you’d use this screw, that drill bit, or some other tool or piece of hardware. It’d be nice if each item had a link to a description of what it was for or how to use it.

[@jadesmith8512]

What in you used zip ties in ever other rivet hole on the flapperon and slowly pulled it together

[@NAvionguy460]

As an A/P I would suggest deburr all holes both sides, you want full part to part contact and some sort of nuts on plastic the screws are fine just add a clipnut

[@n206ja]

I wonder if that primer Zenair applied is actually Cortec? Normally, it has a clear or milky-looking appearance, and if sufficiently thinned, goes down fairly evenly. I guess it could have been dyed, but whatever Zenair used is the color of Zinc Chromate, but I thought that wasn't used anymore due to toxicity! In any event, the parts you deburred and re-primed look 100% better!

[@KitplaneEnthusiast]

I'm not sure it's Cortec. I assume it is because that's what I thought Zenith uses. Maybe it's a different product?

[@schlollepop]

Welcome to the Deburring Channel.

[@Atomsk102]

Burred, Burred, Burred, Deburred is da' word!

[@DavidBruner_NJ]

I noticed you backing wood is not full length and the front guide wood is also short. Place wood full length behind and in front of the flaparons prior to trying. It will go smoother.

[@KitplaneEnthusiast]

Yes I agree. That's one of the reasons we stopped working on it-I didn't have a longer 2x4.

[@gl7080]

Hello Mark, Thanks for sharing. I also want to ask you if you have thought to the option to make a (extra) aluminium strip and glue it on the inside of the plastic wingtip where the screws going. I make's it easier to reinstall it and the plastic be protect for again in and out screwing several times screws. Aluminium will be self taped. Maybe also using few nuts (as used by your inspection gates) into the aluminium strip will help and do the job more secure. I hope this helps you and greeting from The Netherlands.

[@Project2Aero]

Bit of a pain, but well worth it!

[@derekanderson7076]

is all the deburring aesthetic, or is it structurally necessary/beneficial?

[@johnreed8872]

Hey Mark... do you think it's possible that Zenith combined assemblies from a quick build kit into a " standard " Super Duty kit in your case?? I haven't seen pre-assembled pieces in any other Zenith build videos before . Considering the high quality of your work , those assemblies are unacceptable! Great work as always , Thanks again , Blue Skies!

[@simitarknut2201]

Before you do the wing root skins you should reach out to a fellow KZbinr who is a master sheet metal former. His name is Ron Covell.

[@semidemi339]

Is deburring a safety thing or a personal preference?

[@thomaselliott9982]

Would Cleco clamps in conjunction with ratchet straps, ratcheted little by little, and a full length 2×4 on both sides do the job with just one person?

[@KitplaneEnthusiast]

We wanted to try straps but we didn't think they would work due to the short chord of the flaperon, but it appears that others have used them and they worked. I'll still wait for a couple more people as I think there's less chance for damage that way. Plus, like someone else already mentioned, I do need to get a longer 2x4!

[@bobfindley6949]

smiling was kind of shock to see you use M.E.K without gloves. Hell that shuff was outlawed years ago, well at least in Calif. but did notice it said Substitute so maybe not the full blown stuff. I do like your attention to detail.

[@carlmccall7198]

Dang man... i cant believe those edges.. they thought that was ok ?

[@rdennis1983]

So are you going to take apart the forward fuselage with the solid rivets?

[@KitplaneEnthusiast]

No

[@titbp4OPP]

Can you help me with this then? I am thinking about ordered the fuselage pre built. (To save time) I will be excruciatingly detailed as well while I build...but surely I can trust Zenith with the construction? Looking for thoughts about this? Thanks and great work!

[@zeninabox9818]

There has got to be the opportunity for a t-shirt logo with something or someone irreverent saying "So and so says.. Always de-burr your holes!" Lolol

[@karlriley1314]

Need to use some ratchet straps with the wood. Rape the straps around the 2x4 and the front and back of the flaperon a ratchet together.

[@KitplaneEnthusiast]

Thanks for the tip. I may try this, or I might just wait and get some help!

[@karlriley1314]

@@KitplaneEnthusiast When you get help you can try it. It may be easier and faster.

[@barrywood5357]

use ratchet straps

[@wb6anp]

I had no help available, so that is what I did.

[@waynegotthardt3233]

Ratchet Straps

[@StubProductions]

Those parts from Zenith assembly are awful. No attention to detail.