Zenith ZODIAC 601 XL User manual

ZODIAC
601 XL
Zenith Aircraft Company
www.zenithair.com
FUSELAGE ASSEMBLY
6-B-6 Page 1 of 7
Revision 2.3 (02/05/08)
© 2002 Zenith Aircraft Co
Clamp the stiffener inside the bottom flange of the firewall.
P/N: 6B6-2
Firewall
P/N: 6B6-1
Firewall Bottom Stiffener
Cleco every other hole as you drill.
Back drill through the
predrilled holes in the
Firewall through the
Firewall Bottom Stiffener
(flange that overlaps
firewall, do not drill bottom
flange).
A4 Rivets

ZODIAC
601 XL
Zenith Aircraft Company
www.zenithair.com
FUSELAGE ASSEMBLY
6-B-6 Page 2 of 7
Revision 2.3 (02/05/08)
© 2002 Zenith Aircraft Co
Layout the aircraft center line.
Check: the center line is
square to the bottom of
the firewall.
Cleco the Firewall Top Stiffener to the Firewall. Expand the predrilled holes
first with a #30 drill then to #20, Cleco every other hole as you drill.
P/N: 6B7-1
Firewall Top Stiffener
A5 Rivets

ZODIAC
601 XL
Zenith Aircraft Company
www.zenithair.com
FUSELAGE ASSEMBLY
6-B-6 Page 3 of 7
Revision 2.3 (02/05/08)
© 2002 Zenith Aircraft Co
Cut a piece of L angle 520mm (photo shows holes drilled in the L angle, this
is done in the next step).
CORNER L ANGLE
Ref: top middle diagram
on drawing 6-B-7
Check: There should be 10mm edge distance on the last hole to the end of
the L angle. Back drill through the predrilled holes in the Firewall through the
L angle and Cleco every other hole.
Mark a center line on the
L angle and align with the
center line of the Firewall.
A5 Rivets

ZODIAC
601 XL
Zenith Aircraft Company
www.zenithair.com
FUSELAGE ASSEMBLY
6-B-6 Page 4 of 7
Revision 2.3 (02/05/08)
© 2002 Zenith Aircraft Co
Back drill and Cleco the Firewall Top Stiffener to the L angle. An angle drill
makes this easy, but is not required.
Note: Be careful that the
Drill Chuck does not
damage the Firewall Top
Stiffener or the Firewall
when drilling.
Note: Once you have
drilled and Clecoed two
holes through the Firewall
Top Stiffener to the L
angle, you can take them
off the Firewall to finish
drilling the remaining
holes.
Mark the flange centerline on the 40mm wide flange.
The stiffener is positioned with the centerline over the pilot holes for the top
and bottom engine mount fitting.
P/N: 6B6-3
Firewall Side Stiffener

ZODIAC
601 XL
Zenith Aircraft Company
www.zenithair.com
FUSELAGE ASSEMBLY
6-B-6 Page 5 of 7
Revision 2.3 (02/05/08)
© 2002 Zenith Aircraft Co
Mark a line from the start of the bend radius to a point 10mm from the end of
the Firewall Side Stiffener. Trim the Firewall Side Stiffener along this line.
P/N: 6B6-3
FIREWALL SIDE
STIFFENER
IMPORTANT: The top
edge of 6B6-3 is even
with the bend tangent
line. Check it is not
pushed up too high into
the radius – this will
cause a gap between the
overlapping flanges)
Align the center line through the engine mount hole, drill, and Cleco both top
and bottom engine mount holes.
Wait to trim the bottom
until after the side
stiffener is Clecoed to the
firewall.

ZODIAC
601 XL
Zenith Aircraft Company
www.zenithair.com
FUSELAGE ASSEMBLY
6-B-6 Page 6 of 7
Revision 2.3 (02/05/08)
© 2002 Zenith Aircraft Co
Back drill and Cleco the Firewall Side Stiffeners to the Firewall through
the predrilled holes.
Trace the bottom of the
firewall on the stiffeners and
trim the stiffeners flush to the
bottom edge of the firewall.
A5 Rivets
Layout the contour of the firewall on the side stiffener 6B6-3. Remove and
trim.
Mark and round off (file) the
point at the end of the
stiffener.

ZODIAC
601 XL
Zenith Aircraft Company
www.zenithair.com
FUSELAGE ASSEMBLY
6-B-6 Page 7 of 7
Revision 2.3 (02/05/08)
© 2002 Zenith Aircraft Co
Remove the stiffener and L angle on the front side of the firewall. Trim
the ends of 6B7-2 to fit inside the firewall flange. Mark a 10mm line on
the backside of 6B7-2 on the top. Clamp, back drill, and Cleco from the
front side of the Firewall.
P/N: 6B7-2
Firewall Reinforcement
Note: Not all holes have
been back drilled in the
photo. Back drill all holes
through 6B7-2 at this time.
Draw a 10mm edge distance line down the L angle. Align the line on the L
angle through the predrilled holes in the Firewall. Drill and Cleco the L
angle to the Firewall.
A4 Rivets