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Zenith ZODIAC CH 601 Series Manual

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ZODIAC CH 601
Series Kit Aircraft
THE FOLLOWING IS A DRAFT MANUAL
This manual has been written and published strictly for informational purpose. It has
been prepared as a guide to facilitate the assembly of the ZODIAC CH 601 kit aircraft. It
is published to supplement (and not replace) the Zenair drawings and manuals. If a
discrepancy arises between this informational manual and the Drawings, the Drawings
always take precedence.
All pictures, diagrams, drawings or graphs, are used for general identification only, and
are not to be taken to represent technical drawings or replicas of exact parts. You should
not consider the educational material in the manual to be the practice of general aviation
nor is it intended for this manual to be a complete account of sheet metal aircraft
technology: It is limited to the scope of the ZODIAC CH 601 aircraft assembly
This manual is not intended to replace, substitute for or supersede any technical
information 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 completeness
of any information published herein and neither ZAC nor its authors shall be responsible
for any errors, omissions, or damages arising out of use of this information. This guide is
printed with the understanding that ZAC and its authors are supplying information but are
not attempting to render engineering or other professional services. If such services are
required, the assistance of an appropriate professional should be sought.
Copyright, 1995-2001 Zenith Aircraft Company

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Summary of Contents for Zenith ZODIAC CH 601 Series

  • Page 1 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 completeness of any information published herein and neither ZAC nor its authors shall be responsible for any errors, omissions, or damages arising out of use of this information.
  • Page 2 HDS OUTBOARD WINGS WORK REPORT Step # Check Parts / Tools 6SV3-6 HDS Rear Bottom Skin .016 (the Skin is PRE-DRILLED for the Ribs L stiffeners & trailing edge) 6SV3-5 HDS Rear Top Skin .025 (the Skin is PRE-DRILLED for the Ribs L stiffeners & trailing edge) L Angles (length = 4feet) Tool: 1 x 2 furring strip (3/4”...
  • Page 3 L ANGLES STIFFENERS L Angles stiffeners are positioned midway between the ribs on the Top and Bottom Skins - except for the first two inboard ribs at ribs #6 and #7 for the wing locker. The aft edge of the top L Angles overlap on top of the Rear Zee flange (right middle diagram on 6F8) 1.
  • Page 4 CRIMP L TO THE SHAPE OF THE RIB REAR Zee Drawing Rev. Description: ZODIAC (L) WING SKIN STIFFENER 1st Edition: 7-96 CH 601 © Zenith Aircraft Company: Mexico Memorial Airport, PO Box 650, Mexico, MO 65265 USA (573) 581-9000 FAX: 573-581-0011...
  • Page 5 SPLICE PLATE & REAR ZEE LAYOUT Rib station #6 is layout on the Rear Zee by the positioning the Splice plate: first mark the postion of the Rib at 24mm from the end of the Splice Plate, then position the Splice plate on the Rear Zee on a 123mm overlap.

  • Page 6: Right Wing

    THE REAR ZEE 123mm PILOT HOLES HOLE RIB #7 16 A5 Drawing Rev. Description: ZODIAC 1st Edition: 7-96 POSITION REAR ZEE CH 601 © Zenith Aircraft Company: Mexico Memorial Airport, PO Box 650, Mexico, MO 65265 USA (573) 581-9000 FAX: 573-581-0011...
  • Page 7 NOSE RIBS The Rib stations are defined by the pre-drilled holes in the Main Spar. A common rivet line through the Nose Rib Flange and the and Rear Rib flange will hold the Ribs on both sides of the Spar web. DESIGN FEATURES OF THE WING SKELETON •...
  • Page 8 AN3 BOLT (TOP AND BOTTOM THROUGH RIB AND SPAR) Drawing Rev. Description: ZODIAC 1st Edition: 7-96 NOSE RIBS, SPAR TIP L CH 601 © Zenith Aircraft Company: Mexico Memorial Airport, PO Box 650, Mexico, MO 65265 USA (573) 581-9000 FAX: 573-581-0011...
  • Page 9 REAR RIBS & REAR TIP RIB Clamp a support angle along the front side of the Rib to help center the Ribs (up and down) on the Spar; unsupported, the day-light corners on the Rear Ribs (the cutout to clear the top and bottom Spar extrusion) make it difficult to judge when the rib is centered.
  • Page 10 REAR TIP RIB 1R+1L t=.016 90 deg. END VIEW Drawing Rev. Description: ZODIAC 1st Edition: 7-96 REAR RIBS AND WING TIP CH 601 © Zenith Aircraft Company: Mexico Memorial Airport, PO Box 650, Mexico, MO 65265 USA (573) 581-9000 FAX: 573-581-0011...
  • Page 11 REAR TOP SKIN V-10 The pre-drilled holes in the Skins will square the Ribs to the Main Spar. Adding tack rivets along the front edge into the extrusion will assure the spar stays straight during construction. 11. Crimp the un-drilled flange of the L angles to add curvature. For an effective crimping tool, refer to page 4 of the Construction Manual CHECK : Compare the curvature of the L angles by holding it up against a Rear Ribs.
  • Page 12 CORNER OF THE TOP SKIN FLUSH WITH THE SPAR V-11 V-11 Drawing Rev. Description: ZODIAC 1st Edition: 7-96 REAR TOP WING SKIN CH 601 (9/97) © Zenith Aircraft Company: Mexico Memorial Airport, PO Box 650, Mexico, MO 65265 USA (573) 581-9000 FAX: 573-581-0011...
  • Page 13 REAR BOTTOM SKIN V-12 Turn the wing over, and support the trailing edge. 16. Crimp the L angles using the bottom curvature of the ribs as a guide. 17. Position the Bottom Skin 6SV3-6. REFERENCE: 6SV3-6, 6SV1-2 SUPPORT: Support the Ribs at the rear using the following block spacers: S6 159 S7 133 S8 107...
  • Page 14 BE CAREFULL TO PLACE THE BLOCK UNDER THE REAR ZEE V-13 V-13 Drawing Rev. Description: ZODIAC 1st Edition: 7-96 SKIN PLACEMENT CH 601 (9/97) © Zenith Aircraft Company: Mexico Memorial Airport, PO Box 650, Mexico, MO 65265 USA (573) 581-9000 FAX: 573-581-0011...
  • Page 15 LEADING EDGE NOSE SKIN V-14 With the wing upside down on the workbench rivet the bottom side of the Nose Skin. Turn the wing over to strap down the top side of the Nose Skin. 21. The bottom side of the Leading Edge is riveted first. REFERENCE: 6SV3-4 LAYOUT: a) Mark the center line of the Leading Edge radius.
  • Page 16 REMEMBER TO USE SPACERS TO SUPPORT THE WING V-15 V-15 Drawing Rev. Description: ZODIAC 1st Edition: 7-96 WING NOSE SKIN CH 601 (9/97) © Zenith Aircraft Company: Mexico Memorial Airport, PO Box 650, Mexico, MO 65265 USA (573) 581-9000 FAX: 573-581-0011...
  • Page 17 WING TIP V-16 Trim the Nose Skin on the same 45 degrees angle as the Rear Tip Rib: tape a marker at the end of a yard stick, lay the yard stick flat on the Tip Rib to trace the Nose Skin. 23.
  • Page 18 NOSE RIB FIBREGLASS 2 REQ. (L & R) V-17 V-17 Drawing Rev. ZODIAC Description: 1st Edition: 7-96 NOSE RIB INSTALLATION CH 601 (9/97) © Zenith Aircraft Company: Mexico Memorial Airport, PO Box 650, Mexico, MO 65265 USA (573) 581-9000 FAX: 573-581-0011...
  • Page 19 AILERONS V-18 The Aileron Tip Ribs 6SV3-3 are installed later after the Fiberglass Wing Tip and End Rib 6SV3-2 have been installed. 26. The Aileron Ribs are positioned in line with the Rear Bibs to create a continuous rivet line. REFERENCE: 6SV3, 6SV4, 6V10 LAYOUT: Use rib station on the Top Skin 6SV3-5 as a template to mark the Aileron ribs stations.
  • Page 20 5A4 IN TOP FLANGE 2A4 IN FRONT FLANGE 4A4 IN BOTTOM FLANGE V-19a V-19a Drawing Rev. Description: ZODIAC 1st Edition: 7-96 AILERON CH 601 (9/97) © Zenith Aircraft Company: Mexico Memorial Airport, PO Box 650, Mexico, MO 65265 USA (573) 581-9000 FAX: 573-581-0011...
  • Page 21 5/16 hole, horn bolted to template 10mm raduis to hole center V-19b V-19b Drawing Rev. Description: ZODIAC 1st Edition: 7-96 AILERON HORN CH 601 (9/97) © Zenith Aircraft Company: Mexico Memorial Airport, PO Box 650, Mexico, MO 65265 USA (573) 581-9000 FAX: 573-581-0011...
  • Page 22 AILERON TIP V-20 Trim the Aileron tip with the Skin Clecoed to the wing. The Aileron Tip Rib is installed at the same angle as the Rear Wing Tip Rib 6SV3-2 30. Aileron Tip Ribs 6SV3-3 REFERENCE: V-21, 6SV3 31. Aileron Horn 6V10-2 REVERENCE: V-19, 6V10, 6V14 TEMPLATE: Cut a plywood template (use thin plywood) to fit against and bottom of the front of the Aileron Skin.
  • Page 23 21 DEG. LINE UP WITH TIP V-21 V-21 Drawing Rev. Description: ZODIAC 1st Edition: 7-96 AILERON TIP RIB CH 601 (9/97) © Zenith Aircraft Company : Mexico Memorial Airport, PO Box 650, Mexico, MO 65265 USA (573) 581-9000 FAX: 573-581-0011...
  • Page 24 WING LOCKER V-22 The cutout in the Top Skin, installation of the hinge 32. Wing Looker door 6SV4-5 REFERENCE: 6V7, 6SV4 LAYOUT: Position the Wing Locker Door 6V7-8 on the Rear Top Skin between Rear Rib #6 and #7, the sides are parallel with the rib rivet lines. Trace around the door. DZUS FASTENERS: The wing locker door is held closed with Dzus Fasteners along the sides and the aft edge.
  • Page 25 SKIN A4 pitch 40 DZUS V-23 a V-23 Drawing Rev. Description: ZODIAC 1st Edition: 7-96 WING LOCKER AND DOOR CH 601 (9/97) © Zenith Aircraft Company: Mexico Memorial Airport, PO Box 650, Mexico, MO 65265 USA (573) 581-9000 FAX: 573-581-0011...