The z-brackets have not gone well.  First, I moved the holes in the wrong direction for the in board brackets.  I quickly ordered replacements from Van’s.   Next, upon riveting the nutplates on, I discovered I was short!  If only I’d known, I would have ordered those too.  A previous error had forced me to use a couple extra nutplates, but even with those I would still be short a couple.  I’ll admit, when I did inventory I didn’t count every rivet and nutplate… it seems I was not shipped enough.  Oh well. I put a call out on Van’s Airforce and to some local builders to see if I can track some down in time for the weekend.

Here are pictures from today’s progress…

I also made the tank attachment angles.

I also noticed I’m having a little trouble getting the bolts to thread properly. After doing a little research I found that boelube helps a fair amount.  I’ll have to try that tomorrow. 

After realizing I had messed up two of the z-brackets, I did the proper research on the Checkoway Method for installing the tanks.  When I have finished fitting the tanks and the z-brackets, I will be sure to write a concise summary of the method.  For now, I needed to assemble the fuel tanks, including baffles to fit to the wings.  This will allow me to ensure proper fit and alignment.  This evening I assembled the right fuel tank and started on the left.  Upon fitting the right fuel tank to the wing, I confirmed that all of my z-brackets should be good, except the inner most one, whose rivets will be outside the proper edge distance parameters.  Given that this is the root z-bracket which will have the most load, I will definitely be ordering a replacement on Monday.  Here are some pictures of the process. 

Well, I’ll start at the end.  I messed this up!  If you are reading this and getting ready to do the z-brackets, make sure you do your homework first.  I was so eager to get moving after my hiatus, I rushed this a little bit and I’m going to have to replace the two innermost z-brackets.  Research the “Checkoway Method” and use that.  Here’s a good link. 

Van’s instructions on this particular step are not good.  So I went to my buddy Mike’s site to see how he did it.  As soon as I started reading, I could tell he didn’t follow Van’s instructions, but I didn’t take the time to fully figure out exactly how he did it….  As a result of my rush, I will not have the proper edge distance on my two inner most brackets.  Oh well.

I’m not going to re-write the whole method as I’ve not yet done it myself, but I will say this about the brackets.  Offset the holes slightly toward the web to allow better clearance for the pop rivet puller.  HOWEVER, the innermost (here’s what I did not do) brackets need to be offset AWAY from the web in order to allow a socket head to fit over the bolt.  Additionally, the rivet holes attaching to the tank will be better positioned with that offset.

Since I messed up the two z-brackets, I decided to move on to the tank construction.  The instructions tell you to make the stiffeners at this point.  That can probably wait till later, but heck, I might as well do it now.  And that brings up to my current progress. 

All marked and ready for drilling.  Sorry, no pictures of the end result.  I’ll post some next time. 

Here are the completed stiffeners.