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Zenith 750 Cruzer When I assembled the aft fuselage I didn't think about mounting the ELT antenna. So I had no stiffener plate or holes drilled for it. I did have a stiffener plate for the comm antenna and the LED beacon I'm using. I know I don't need the beacon, but it's just too cool not to have!

Shown here is the location of the beacon. Unfortunately, it's also the perfect place to mount the ELT antenna.

   
Zenith 750 Cruzer Here is the hole drilled for the beacon. I've decided to mount the ELT antenna here and then move the beacon further aft...if I can reach back there to mount it.

This hole is too big for the ELT antenna so I have to make a cover for it.

   
Zenith 750 Cruzer Oh, here's the LED beacon. It is white, but when it lights up it is red.
   
Zenith 750 Cruzer First step was to drill out the rivets.
   
Zenith 750 Cruzer Then I cut a plate to fit over all the rivets.
   
Zenith 750 Cruzer Under the top skin is a stiffener plate. That's shown here as the grey primed piece under the new top plate. I'm match drilling the holes in the new plate.
   
Zenith 750 Cruzer A new smaller hole was drilled in the new plate to fit the antenna. I will still use the grey plate under the skin just for added strength. I just can't rivet it until I find another person to put clecos in while I crawl in the fuselage and insert the grey stiffener again!

The new stiffener plate is highly visible in the photo, but it's almost invisible when you see it in person. Once the plane is painted I don't think anyone will notice it. I don't particularly like having it on the outside, but there's no other way to do it if I want to mount the ELT antenna here.

   
Zenith 750 Cruzer Here's a zoomed out view showing the location of the comm antenna and the ELT antenna.
   
Zenith 750 Cruzer Here's an update-I didn't like the looks of a square plate on top of the fuselage. So I modified it into a cool star shape.

I still have the big square stiffener under the skin, and the star is on top.

   
Zenith 750 Cruzer I think it looks so much better. The new shape makes it look like it's suppose to be there and it's not just some square afterthought.
   
Zenith 750 Cruzer Top view.
   
Zenith 750 Cruzer Next task was to make and install the rudder cables. Here they are all done. Since the cables cross, you need some sort of plastic to separate them. I went to the local hobby shop and bought R/C airplane pushrods and cut them to length.

These are the Sullivan brand push rods. They come with two yellow pushrods and the blue is actually the sleeve for the pushrods. Shown here I cut off about 1/3 of the blue sleeve to use for the rudder pedals, and the other 2/3 I used on the elevator cables.

REMEMBER to install these sleeves before you nicopress on both ends! Same with the heat shrink.

   
Zenith 750 Cruzer  
   
Zenith 750 Cruzer Here they are minus the cotter pins.
   
Zenith 750 Cruzer Notice I used white nylon washers between the shackle and the tab on the pedal. They are super thin and work amazingly well here for this application. I have them installed on every shackle on the plane. It really makes the movement smooth as the metal is rotating on the nylon bushing instead of the metal tab.
   
Zenith 750 Cruzer Every year at Oshkosh I go to the fly market and visit one of the popular venders that sells aircraft hardware; I can't remember who it is. The package here says B&B with a phone number.

They have tons of aircraft hardware and I pick up nuts, bolts, clamps, and anything else I think I might want in the future. I just like to have a large stock of parts like this.

As you can see, last year I bought this bag of nylon washers for $2.00. I had no idea what I would ever use them for but now I have the perfect use for them.

   

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