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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

Home or Last Project Picture

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.

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A3310128 Step Assembly.pdf

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.

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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.

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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.

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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.

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

Category: Fuselage

Finish welded front shoulder harness attached points.

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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.

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Jun 13, 2020 Rear fuselage tabs with nutplates - (2 hours)

Category: Fuselage

Finished nutplate tabs and welded to rear fuselage in front of tailwheel. Eight total.

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Jun 10, 2020 Nut plates - (1 hour)

Category: Fuselage

Drilled eight tabs for nut plates to attach rear fuselage plate

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Jun 07, 2020 Floorboard tabs for extended Baggage - (1.5 hours)

Category: Fuselage

Fitted, tack welded, and finish welded tabs for extended baggage area

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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

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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.

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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.

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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.

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May 30, 2020 Installed floorboard tabs - (1 hour)

Category: Fuselage

Drilled holes, installed rivet nuts and tack welded floorboard tabs into place

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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.

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May 23, 2020 Shoulder harness attach fittings - (1 hour)

Category: Fuselage

Fabricated shoulder harness attach fittings

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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.

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May 17, 2020 Fabricated and tack welded fuselage handle - (2 hours)

Category: Fuselage

Bent, cut, and fit to fuselage grab handles. Tack welded into place.

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May 08, 2020 Removable Cross Tube-Rear Seat Back Rest - (3 hours)

Category: Fuselage

Cut out cross tube from fuselage in order to prepare it to be a removable piece

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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.

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Apr 15, 2020 Upper Baggage Door Frame - (2 hours)

Category: Fuselage

Framed in upper baggage door.

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Apr 12, 2020 Lower baggage door - (3 hours)

Category: Fuselage

Fabricated lower baggage door frame.

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Apr 08, 2020 Lower Baggage Door - (2 hours)

Category: Fuselage

Fabricated fit up and tack welded lower baggage door lower edge.

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Apr 02, 2020 Rear Rudder Pedals - (2 hours)

Category: Fuselage

Wind rear rotor petals. Ready for tack welding.

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Mar 23, 2020 Rudder Pedal Brackets - (3 hours)

Category: Fuselage

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Mar 16, 2020 Turtle deck and Rear Window Frame - (4 hours)

Category: Fuselage

Finish the last stringer on the turtle deck. Also welded in the D frame rear windows

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Feb 29, 2020 Turtle Deck Install - (3 hours)

Category: Fuselage

Fit and welded on turtle deck tabs for the back bone

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Feb 28, 2020 Fabricated More Turtle Deck Tabs - (1 hour)

Category: Fuselage

Fabricated more of the turtle deck tabs; drilled, deburred and bent.

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Feb 26, 2020 Turtle deck attachments

Category: Fuselage

Fabricated first of many attachments.

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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.

Dec 14, 2019 Seat belt attachment

Category: Fuselage

Located and welded seatbelt attach fittings

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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.

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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.

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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.

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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.

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Oct 27, 2019 Upper Door Frame

Category: Fuselage

Work continued on right upper door frame.

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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.

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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.

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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.

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Oct 05, 2019 Door frame - (2 hours)

Category: Fuselage

Cut, bent, fit, and tack welded door frame in place on each side.

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Sep 11, 2019 Stirrup - (2 hours)

Category: Fuselage

Fabricated the stirrup
81903

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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.

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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.

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Jan 31, 2019 Welding Rudder Tabs

Category: Fuselage

Welded rudder and floor board tabs onto fuselage #1.

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Aug 19, 2018 Extended Baggage

Category: Fuselage

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Jun 29, 2018 Tail Wires

Category: Fuselage

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Jun 27, 2018 Tail wire attachment

Category: Fuselage

Heat formed tail flying wire attachments.

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Dec 05, 2017 Pulley Alignment

Category: Fuselage

Installation of forward pulley

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Dec 16, 2016 Trying on the Fuselage for size

Category: Fuselage

Trying on the Fuselage for size

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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.

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Dec 04, 2016 Forward Cockpit Tubing

Category: Fuselage

Forward Cockpit Tubing

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Dec 04, 2016 Fuselage Tubing in Front of Cockpit

Category: Fuselage

Fuselage Tubing in Front of Cockpit

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Dec 04, 2016 Forward Tubing

Category: Fuselage

Fit up tubing in front of cockpit.

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Dec 01, 2016 Fixturing up the motor mount fittings.

Category: Fuselage

Fixturing up the motor mount fittings.

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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.

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Nov 25, 2016 Cathedral Baggage

Category: Fuselage

Fixturing the baggage area bump out.

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Oct 26, 2013 Auto Entry: Oct 26,2013

Category: Fuselage

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Mar 03, 2012 Piper Channel

Category: Fuselage

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Oct 19, 2011 Auto Entry: Oct 19,2011

Category: Fuselage

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Sep 05, 2011 Fuselage Tailpost

Category: Fuselage

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Sep 02, 2011 Fuselage Firewall

Category: Fuselage

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Aug 13, 2011 Top of Fuselage

Category: Fuselage

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Aug 11, 2011 Fuselage Frame Up

Category: Fuselage

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Jul 15, 2011 Fuselage Completely Tacked

Category: Fuselage

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Jul 15, 2011 Fuselage Overview

Category: Fuselage

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Jul 15, 2011 Tail post

Category: Fuselage

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Jul 10, 2011 Auto Entry: Jul 10,2011

Category: Fuselage

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Jul 08, 2011 Fuselage

Category: Fuselage

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Jun 18, 2011 Reverse Dogleg

Category: Fuselage

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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.

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Apr 20, 2011 Fuselage Sides

Category: Fuselage

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Apr 05, 2011 Fuselage Side construction

Category: Fuselage

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Apr 03, 2011 Bending Longerons with Tubing Bender

Category: Fuselage

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Mar 28, 2011 Layout

Category: Fuselage

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Mar 28, 2011 Fuselage Layout

Category: Fuselage

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