LM701  STOL N1345L

Construction Tips

Following are construction hints and some of the tool I have built.

Corrosion Protection.  Corrosion protection is important, but how much depends on several factors.  Where you fly, if your aircraft is stored inside or outside and the all present weight factor.  A minimum amount should always be applied.  If you live and fly near salt water or you aircraft is stored out side then a maximum amount should be applied.  My aircraft is stored inside a totally weather proof hanger and no where near salt water.  Of course the entire outside has protection on it anyway from paint and primer, but internally I apply Zinc Chromate to one side of any surfaces that is in contract with another.  It is not necessary to apply it to both surfaces, for example, apply it to the rib edges but not the underside of the skin.  Like this.

In the picture you can see where the top of the ribs are protected, but not the sides.  The back of the ribs are not protected, but the main spar to which they are riveted is totally covered with protection.  If I were in more sever conditions, everything would be protected.  It is only necessary to apply a very thin coat, it does matter if you can see though it, the thinner the better.   Don't forget to use a good cleaner/acid wash first.  Here's my stuff.  I use the little spray gun for larger parts and the little brush for edges, etc.

Drilling.  Here's a little trick that will save you from marking up your aluminum when drilling.  Take a piece of small vacuum hose and put it long ways over the drill bit with only a little part of the bit showing.  Here's mine.

On the PegaStol wings and some Zenith parts the rivet holes are piloted.  PegaStol uses a computer controlled hydro cutter, Zenith uses a manual punch system.  The PegaStol pilot holes are too small to see through.  One of the first things I do is drill out all the pilot holes to 3/32, fits silver clecos.  This will allow you to see your center lines on the ribs, etc. 

When you drill out hundreds of holes it is a good idea to place your material on a piece of plywood and place the covered bit between your fingers and press down.  You will have less burrs and no distortion.

Moving large sheets of aluminum.  If you have to work alone most of the time like I do then you have to figure out ways of doing stuff my yourself.  Moving those large sheets of .016 aluminum around is next to impossible to by yourself without bending them.  What I do is cleco 1"X4" boards to the leading edge with silver clecos.  On most sheets for both Zenith and PegaStol, one edge is pre-drilled, use that.  Here's a picture of me moving a 14' sheet, no problems.

Tools.  There are some tools you will need to buy, borrow or make that they don't tell you about until you need them.  Here's a few I made.

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