Project: cbecker   -  
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Builder Name:Charlie Becker   -  
Project:   Pirate Cub   -   VIEW REPORTS
Total Hours:103.5
Start/Last Date:Jan 30, 2011 - No Finish Date
 
Friendly URL: https://eaabuilderslog.org?s=cbecker

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May 18, 2021     Auto Entry: May 18,2021       Category: Auto Entry


 
Apr 10, 2021     Auto Entry: Apr 10,2021       Category: Wings


 
Jan 06, 2021     Right flap - (2 hours)       Category: Wings


 
Dec 08, 2020     Deburr Right Aileron - (1 hour)       Category: Wings


 
Nov 15, 2020     Right aileron - (3 hours) Category: Wings
Continue to work on right aileron.
 
Nov 10, 2020     Left Aileron - (2 hours)       Category: Wings
Started on left aileron


 
Oct 17, 2020     Aileron riveting - (3 hours)       Category: Wings
Put the left aileron back in the fixture and started riveting


 
Oct 11, 2020     Riveting Flap - (3 hours)       Category: Wings
Riveted flap


 
Oct 02, 2020     Right Flap       Category: Wings
Drilled gussets.


 
Aug 07, 2020     Aileron Tail Ribs - (1 hour)       Category: Wings
Riveted tail ribs


 
Aug 07, 2020     Auto Entry: Aug 7,2020       Category: Auto Entry


 
Aug 06, 2020     Auto Entry: Aug 6,2020       Category: Flaps
Cutting wood for jig board for putting washout into the ailerons and flaps


 
Aug 02, 2020     Riveting Ailerons - (2 hours)       Category: Wings
Riveting aileron hinges. Neeeded to grind down the nose of the squeezer for proper access.


 
Jul 28, 2020     First Squeezed Rivets - (1 hour)       Category: Wings
Figured out rivet squeezing and set the first few rivets.


 
Jul 26, 2020     Riveted Control Horn onto Aileron - (1 hour)       Category: Wings
It helps to have friends when building an aircraft. The ailerons require 8 driven rivets "soft steel rivets" (4 per side). These must be done using a rivet gun. Rather than training up for 8 rivets, I enlisted an RV builder to set those rivets for me. He was able to do it using a tungsten bucking bar rather than the "special" bucking bar.


 
Jul 19, 2020     Unpacked Kit       Category: Wings
Unpacked some of the wing kit. The quality is top notch.


 
Jul 17, 2020     Trip to Javron to pick Up Wing Kit       Category: Wings
John and I drove to Javron Aviation in Brainerd MN to pick up a wing kit. Long day of driving but well worth it!


 
Jul 08, 2020     New TIG welding cup       Category: Tools
Testing out a new TIG welding cup.


 
Jul 07, 2020     Fabricated step - (1 hour)       Category: Fuselage
Fabricated rear step (stirrup) by bending and cutting and tack welding tubing. Followed the Wag Aero plans rather than PA-18 as it was easier to fabricate.


 
Jul 04, 2020     Brake pedal reinforcement bracket - (1 hour)       Category: Fuselage
Brake pedal reinforcement bracket Installed. Piper bolts this to the floorboard however I welded it to the fuselage frame. Next step is to drill the petal clamp holes.


 
Jul 04, 2020     Upper baggage compartment floorboard - (1 hour)       Category: Fuselage
Used template to cut and fit upper baggage compartment floorboard. Cut down the center and will install piano hinge later. The floorboard is very light weight since we made it out of composite materials.


 
Jun 28, 2020     Upper Baggage Shelf - (2 hours)       Category: Fuselage
Use template to determine the size of upper baggage shelf. Also added some piper channel reinforcement supports.


 
Jun 20, 2020     Rear shoulder harness attached point - (1 hour)       Category: Fuselage
Made template, cut material, deburred, and drilled holes for rear shoulder harness attach point fitting.


 
Jun 16, 2020     Finish welded front shoulder harness attached points - (.5 hour)       Category: Fuselage
Finish welded front shoulder harness attached points.


 
Jun 14, 2020     Fabricated fairlead holder - (1 hour)       Category: Fuselage
With the help of my friend Lee, fabricated 10 fairlead holders out of 7/8 x .058 tubing.


 
Jun 10, 2020     Nut plates - (1 hour)       Category: Fuselage
Drilled eight tabs for nut plates to attach rear fuselage plate


 
Jun 06, 2020     Shoulder harness attached points - (1 hour) Category: Fuselage
Determine where to attach shoulder harnesses. Use 10 inch center to center of hole spacing. Based on Bill Ross advice. He said that's what the Boeing he flies has. Tack welded in place
 
Jun 06, 2020     Shoulder harness attached points - (1 hour)       Category: Fuselage
Determine where to attach shoulder harnesses. Use 10 inch center to center of hole spacing. Based on Bill Ross advice. He said that's what the Boeing he flies has. Tack welded in place


 
Jun 03, 2020     Cut and fit floorboard for extended baggage compartment - (2 hours)       Category: Fuselage
Cut and fit plywood into the extended baggage compartment based on cardboard template. Used 1/4"" Baltic Birch plywood from Menards. The cuts were not one straight line as the fuselage curves back to the tail. We were able to use the straight edge but each side had to be divided into three straight cuts. Used a jigsaw and taped both sides of the plywood to limit breakout.


 
May 31, 2020     Seat belt bushings - (1 hour)       Category: Fuselage
Found bushing stock material at Fleet Farm to reduce the hole size from 1/2 to 3/8. Cut to size, deburred and press fit into place on seat belt attached fitting.


 
May 31, 2020     Extended baggage rivet nuts - (1 hour)       Category: Fuselage
Laid out, and drilled holes for rivet nuts needed to secure floorboards. Using 8-32 rivet nuts.


 
May 30, 2020     Installed floorboard tabs - (1 hour)       Category: Fuselage
Drilled holes, installed rivet nuts and tack welded floorboard tabs into place


 
May 30, 2020     Rear control stick attached point - (1 hour)       Category: Controls
Fabricated and tack welded attached point for rear throttle lever


 
May 24, 2020     Extended baggage floorboard - (2 hours)       Category: Fuselage
Create a template out of poster-board to determine size of extended baggage floorboard and then cut it out of thick cardboard to test it out.


 
May 23, 2020     Shoulder harness attach fittings - (1 hour)       Category: Fuselage
Fabricated shoulder harness attach fittings


 
May 22, 2020     PTT Button       Category: Avionics
Ordered these for possible use as Push To Talk buttons.
Coolais 5 Pcs Momentary Push Button Switch Metal Waterproof Push Button Start 12mm 3A 250V AC PBSM-02 (High Head)


 
May 22, 2020     Front Seat Belt       Category: Fuselage
Ordered RaceQuip 741001 Sportsman 5-Point Camlock Harness Set. These are 3 inch wide belts with a camlock. I'm going to use these in the front and then decide about the back. The belts are heavier duty than I was expecting.


 
May 13, 2020     Horn for trim tab - (2 hours)       Category: Tail Feathers
Fabricated control horn for trim tab and tack welded in place


 
Apr 28, 2020     Finished welding trim tab - (1 hour)       Category: Tail Feathers
Finished welding the trim tab. Closed off the hole in the tubing on both ends. Finish welded floor board/rudder pedal supports.


 
Apr 24, 2020     1 inch Belt Sander       Category: Tools
Highly recommend this tool. Do not get the one with the side disk. This set up allow for lots of access when sanding parts. This one is from Harbor Freight.


 
Apr 23, 2020     Trim tab - (2 hours)       Category: Tail Feathers
Sheared and formed material for Leading and trailing edge out of .032 4130. Cut the middle rib away so that I could then build the trim tab in place.


 
Apr 19, 2020     Trim Tab - (1 hour)       Category: Tail Feathers
Plans for trim tab. Reviewed and put a plan together


 
Apr 19, 2020     Brake pedal support fabrication - (3 hours)       Category: Fuselage
Started on fabrication of the brake pedal reinforcement. Using the cutoff wheel on the Dremel tool. First drilled some holes in the corners with a step drill to provide a radius.


 
Apr 15, 2020     Upper Baggage Door Frame - (2 hours)       Category: Fuselage
Framed in upper baggage door.


 
Apr 08, 2020     Lower Baggage Door - (2 hours)       Category: Fuselage
Fabricated fit up and tack welded lower baggage door lower edge.


 
Apr 02, 2020     Rear Rudder Pedals - (2 hours)       Category: Fuselage
Wind rear rotor petals. Ready for tack welding.


 
Feb 28, 2020     Fabricated More Turtle Deck Tabs - (1 hour)       Category: Fuselage
Fabricated more of the turtle deck tabs; drilled, deburred and bent.


 
Feb 26, 2020     Turtle deck attachments       Category: Fuselage
Fabricated first of many attachments.


 
Jan 22, 2020     Welding Clean Up Category: Fuselage
Good to back in the shop. Spent the evening finishing off some welds; primarily on the door frame.
 
Nov 28, 2019     Left Upper Door       Category: Fuselage
Fabricated the upper left side door- I used two tools that may be of help to other builders. The first is this cheap little angle finder that is very useful for aircraft stuff given it's small size. The other is this digital angle finder. I used both depending on the area I was trying to fit the tool.


 
Nov 23, 2019     Hinges for upper door Category: Fuselage
 
Nov 23, 2019     Hinges for upper door       Category: Fuselage
Welded on the hinges for the upper door frame. If you look at the first photo, used a piece of angle iron to keep the hinge square. Also used washer under the door as a standoff to allow the hinge to stick out from the door frame.


 
Nov 19, 2019     Upper Door Frame Verticals       Category: Fuselage
Fitted and welded in verticals on the upper door frame that will attach the windshield to.


 
Nov 19, 2019     Upper Door Frame Verticals       Category: Fuselage
Fitted and welded in verticals on the upper door frame that will attach the windshield to.


 
Oct 27, 2019     Upper Door Frame       Category: Fuselage
Work continued on right upper door frame.


 
Oct 21, 2019     Upper Door Frame       Category: Fuselage
Cut and fit tubing for upper door frame on right side of fuselage. Ready for tacking. Used some strips of wood to provide the appropriate uniform spacing. At first I just eyeballed the joint, but after having problems with the fit up, I measured the angle, then divided by two to determine what angle I really wanted. This really helped dial in the fit up.


 
Oct 20, 2019     Starting on Upper Doors       Category: Fuselage
Using a sheet of particle board to provide a flat surface for the upper door frame.


 
Oct 15, 2019     Upper Door Frame Reinforcement       Category: Fuselage
Fit and tack welded some supports for the upper door frame. Used a wood template to determine where to place the supports to avoid any fuel lines.


 
Sep 29, 2019     Rudder pedal - (1.5 hours)       Category: Controls
Fabricated and welded the last rudder pedal.


 
Aug 25, 2019     Panel-Carbon Cub       Category: Research
SNF 2017 Carbon Cub panel


 
Aug 25, 2019     Panel-Minimalist       Category: Research
SNF 2017 Cub-Minimalist panel


 
Aug 25, 2019     Panel-Legend Cub centered on iPad       Category: Research
I saw this panel at SNF 2017 in a Legend Cub. This Cub was on floats.


 
Aug 14, 2019     Welded gear leg step - (1 hour)       Category: Landing Gear
Finish welded right gear leg step crossed tube.


 
Aug 13, 2019     Landing Gear reinforcement - (2 hours)       Category: Landing Gear
Added upper and middle cross tubes for landing gear. Top cross tube was 1/2 x.035 and middle was 7/8 x .035. The middle tube will also act as a step.


 
Aug 11, 2019     Added Step - (1 hour)       Category: Landing Gear
Copying off what Javron Aircraft does, added a reinforcing crossmember that can also function as a step to get in and out of the aircraft. Tube is 7/8 x .035.


 
May 21, 2019     Load Test of Rib to 300 pounds       Category: Wings
Static load test of rib to 300 pounds. After removing the weights, it appear there was no deformation.


 
May 18, 2019     Load Test of Rib       Category: Wings
Since I'm deviating from the Piper Super Cub rib construction (just can't be made by a homebuilder), I wanted to verify that my rib would be at least as strong as the Piper rib. Here is a basic load test with 200 lbs of weight hanging from the rib. In order to keep the rib vertical, we clamped a couple of pieces of wood next to the capstrips because without the fabric covering to keep it veritcal, the rib would have leaned over an failed. We used a jack to allow us to slowly apply the load to the rib. This should equate to a 2,000 pound gross weight aircraft. More test to follow.
My rib is significantly heavier than Piper's (all kit ribs are because Piper was really smart about how they designed and built their rib).
Overall I'm happy with the results and now may look at reducing the weight by using some light weight aluminum and testing again.


 
May 18, 2019     Load Test of Rib Category: Wings
Video of load test of wing rib
 
May 15, 2019     Prototype Rib #1       Category: Wings
Prototype rib based on Ed Fisher's capstrip concept.


 
Feb 17, 2019     Tail Feathers Installed       Category: Tail Feathers
Installed tail feathers and tail brace wires.


 
Feb 16, 2019     Reinforced rear fuselage       Category: Fuselage
Added a couple of extra 1/2 tubes in an X pattern to reinforce the rear fuselage as it will get a lot of abuse.


 
Feb 03, 2019     Attached Rudder       Category: Fuselage
Spent quite a bit of time aligning the rudder and then a little time tack welding the hinges.


 
Jan 31, 2019     Welding Rudder Tabs       Category: Fuselage
Welded rudder and floor board tabs onto fuselage #1.


 
Aug 19, 2018     Extended Baggage       Category: Fuselage


 
Jun 29, 2018     Tail Wires       Category: Fuselage


 
Jun 27, 2018     Tail wire attachment       Category: Fuselage
Heat formed tail flying wire attachments.


 
Dec 05, 2017     Pulley Alignment       Category: Fuselage
Installation of forward pulley


 
Nov 22, 2017     Vertical Fin       Category: Empennage
Construction of the vertical fin.


 
Dec 16, 2016     Trying on the Fuselage for size       Category: Fuselage
Trying on the Fuselage for size


 
Dec 11, 2016     Lower Door Construction       Category: Fuselage
Lower Door Construction. Note: I made this out of square tubing from Menards. After building it, determined it was too heavy and did not use it.


 
Dec 04, 2016     Forward Tubing       Category: Fuselage
Fit up tubing in front of cockpit.


 
Dec 01, 2016     Fixturing up the motor mount fittings.       Category: Fuselage
Fixturing up the motor mount fittings.


 
Nov 28, 2016     Trimming the Longerons       Category: Fuselage
Always leave the longerons longer than you need for welding and then come back and trim to size. Your welder will thank you. I'm now getting ready to fit the motormount attach fittings.


 
Nov 25, 2016     Cathedral Baggage       Category: Fuselage
Fixturing the baggage area bump out.


 
Dec 08, 2013     Auto Entry: Dec 8,2013       Category: Auto Entry


 
Mar 04, 2012     Auto Entry: Mar 4,2012       Category: Auto Entry


 
Mar 04, 2012     Auto Entry: Mar 4,2012       Category: Auto Entry


 
Feb 29, 2012     Auto Entry: Feb 29,2012       Category: Tail Feathers


 
Jan 30, 2012     Auto Entry: Jan 30,2012       Category: Auto Entry


 
 
Jul 08, 2011     Fuselage       Category: Fuselage


 
Jun 18, 2011     Reverse Dogleg       Category: Fuselage


 
Jun 12, 2011     Rosette Weld       Category: Fuselage
The lower longeron transition from 3/4"" tube to a a 5/8"" tube. A rosette weld is used along with welding the end of the tube to secure it in place.


 
Apr 20, 2011     Fuselage Sides       Category: Fuselage


 
Mar 28, 2011     Layout       Category: Fuselage


 
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