Construction Log

Zenith Zodiac 601HD

SN: 6-3951

Builder: Chris Boultinghouse

Date and Comments

Time

Cost

01 Jan 99:

No building. Recovering. See previous entry.

0.0 hrs

$0.00

02 Jan 99:

No building. Doing plumbing work to move washing machine into workshop. All day job with much crawling under house. Ugh.

0.0 hrs

$0.00

03 Jan 99:

Cut S6 and S8 rear ribs. Marked and cut S7 rear rib. Sanded 1/8" radius on center nose rib forming edge.

3.0 hrs

$0.00

04 Jan 99:

No building. Creating new web site to chronicle building process.

0.0 hrs

$0.00

05 Jan 99:

No building.

0.0 hrs

$0.00

06 Jan 99:

No building.

0.0 hrs

$0.00

07 Jan 99:

Sanded rear rib blocks to final dimensions using disk sander. What a mess! Turned the entire shop a nice light tan with sawdust. Halfway finished with rib forming blocks!

1.0 hrs

$0.00

08 Jan 99:

Marked out remainder of rib blocks using completed blocks as the pattern. Hand sanded 1/8" radius on existing nose rib blocks and drilled holes. Didn't have enough MDF for all rear ribs; will purchase more tomorrow.

1.0 hrs

$0.00

09 Jan 99:

Purchased another sheet of MDF. Marked remainder of forming blocks. Radiused edges on remaining nose rib blocks and one rear rib block.

1.0 hrs

$4.29

10 Jan 99:

Cut remainder of rib forming blocks. Varnished those that are already radiused.

3.5 hrs

$0.00

11 Jan 99:

No building.

0.0 hrs

$0.00

12 Jan 99:

Match drilled holes in all rib blocks. Clamped and match sanded all rib blocks on disc sander.

2.0 hrs

$0.00

13 Jan 99:

No building. Migraine.

0.0 hrs

$0.00

14 Jan 99:

No building. Rented a movie and spend the evening with the better half.

0.0 hrs

$0.00

15 Jan 99:

No building.

0.0 hrs

$0.00

16 Jan 99:

No building. Cutting firewood.

0.0 hrs

$0.00

17 Jan 99:

Finished hand sanding, radiusing and varnishing all rib form blocks. Time to bend some metal now.

4.0 hrs

$0.00

18 Jan 99:

No building.

0.0 hrs

$0.00

19 Jan 99:

No building.

0.0 hrs

$0.00

20 Jan 99:

No building. Purchased 4x12 sheet of .025 6061-T6 from local metal distributor. Material is made by Kaiser in Houston, TX.

0.0 hrs

$60.62

21 Jan 99:

Used CAD to determine best arrangement for outer ribs on aluminum sheet.

1.0 hrs

$0.00

22 Jan 99:

Unrolled aluminum and laid out outer rib patterns. Began by marking precisely 20mm from blocks, but realized it would be better to cut oversize and mark/trim final dimensions after bolting together on the forming blocks. Began cutting blanks only to realize I needed all three varieties of WISS snips (left, right and straight) for best results. Store already closed. Finished for the night!

2.5 hrs

$0.00

23 Jan 99:

Purchased two additional pairs of WISS snips. Now have left, right and straight cut varieties. Rough cut all blanks. Marked, cut and filed S6 and S7 nose rib pairs. Made fluting pliers

3.0 hrs

$19.90

24 Jan 99:

Pounded out S7 nose rib pair. Fluting pliers work great! Marked and final trimmed S7 rear rib blanks.

2.0 hrs

$0.00

25 Jan 99:

No building.

2.0 hrs

$0.00

26 Jan 99:

No building.

2.0 hrs

$0.00

27 Jan 99:

Finished edges of S7 rear blanks and formed both S7 rear ribs. Reworked flange corner radius on both S7 nose ribs.

1.5 hrs

$0.00

28 Jan 99:

No building.

1.5 hrs

$0.00

29 Jan 99:

Formed both S6 nose ribs.

1.0 hrs

$0.00

30 Jan 99:

Marked all remaining outboard ribs to final dimensions. Drilled all alignment holes. trimmed and smoothed remaining nose ribs. Formed left S9 nose rib. The smaller they are, the harder it is to get the flange right. I can't wait to do the rudder ribs....

3.0 hrs

$0.00

31 Jan 99:

Purchased adjustable circle cutter to make lightening holes. While browsing the Home Depot I also picked up a Sure Form plane, file cleaning brush, some non-slip bench mat and a swivel head deburring tool. Trimmed all remaining outboard ribs to final dimensions. Deburred and smoothed all edges. The deburring tool works great! Used circle cutter to cut the 95mm lightening hole in both S6 nose ribs. After slicing a nuckle on the circle cutter, mashing another finger on the same hand between two boards and pinching a blood blister on a finger of the other hand with the drill press chuck I decided to call it a night! All of this damage occurred within five minutes, I might add. Sometimes I wonder about myself. Oh well, at least "first blood" has been drawn on this project and I can move along without wondering when it will happen.

4.0 hrs

$41.68