Jan 21, 2024     Starting on wing ribs - (7 hours)       Category: Wings

Starting on the structure of the wing. I was able to find a vendor on Ebay selling 7/8" sheets of honeycomb aluminum panels. I purchased 7 panels, planning on making 4 ribs per panel. I took a page from my full sized plans and cut out the wing profile, and glued it to a piece of thin plywood. Sanding the edges, I created a drawing and size template. I got out my table saw, and cut my panels down to 7.5 inch wide strips. Using my template I drew the wing profile on each of my strips and using my bandsaw , cut them to rough size. A few minutes work on the belt/disc sander and I have a rib. Only 27 more to go!

  Jan 02, 2024     Aileron support bracket and Bellcrank - (16 hours)       Category: Controls

The positioning of the aileron bellcrank and bearing is dependant on the wing and specifically the rear spar. I wanted to weld, so I started searching the garage for my raw materials, cutting pieces to size. Once everything was sized properly, I broke out the TIG. Welding is becoming my favorite task. Some minor fit and finishing work, and everything looks as it should.

  Dec 04, 2023     Center tunnel and flap lever support - (4 hours)       Category: Fuselage

Starting the center tunnel that houses the rudder cables and the elevator pushrod. This will also support the Flap handle in a fashion similar to the Piper Warrior's I've flown in the past. Obtained a very functional handle and will mount it soon.

  Oct 15, 2023     Controls and instrument panel - (8 hours)       Category: Controls

Playing around in the garage. Had a temp wood mock up to hold the bearing support for the control yoke. Replaced with a proper piece of angle aluminum and support to hold the bearing mounts. The IP will be in front of this and will be supported top and bottom. A previously used scrap of cardboard supports cut outs for the panels for AHERS, Navigation and EIS. The EFIS and Nav will be interchangeable via wi-fi connectivity and allow for passenger participation as well as I pad failure. Seats are re-installed to check on overall ergonomics and reach.

  Aug 01, 2023     Virginia Patriot mod - (6 hours)       Category: Empennage

The BD-4 has had many mods advocated during it's lifespan. Longer wings, metal wings, landing gear, the changes are numerous. Today I accomplished one if the simpler ones advocated by Don Hewes. The brace in the tail section that supports the tailwheel and helps prevent damage during harder landings. It requires welding, and I've got a great Tig welder and have been putting together metal for the last couple of years. Here's today's effort.

  Jul 31, 2023     Completed horizontal stab - (40 hours)       Category: Empennage

Completed work on the rough Horizontal Stab. Finished installing the wing ribs, securing them all in place. Installed a bracket and mount for my autopilot servo that will actuate a trim tab attached to the rear edge. Cut skins to size, fit in place, and started to drill holes for cleco and eventually rivets. Many holes to drill, many rivets to pull. Ran out of rivets and had to order more. Closed in skin, cut hole for autopilot bellcrank, fabricated trim tab, riveted hinge and bracket to tab, and attached to rear of fuselage. With my son's help, was able to trial fit to fuselage, clearance skins for mount bolts and sides of fuselage. Preliminary hard mount shows full range of motion w/o interference. Stab is level and appears to be solid. Need to finish fairings, mount for counterweight, after cover box and counterweight bracket for trim tab.

  Jun 28, 2023     Horizontal Stab work - (16 hours)       Category: Empennage

Started on the Horizontal Stab this week. I love NOS parts. Look at the date on the rib! All looks good and level. Riveting done, aft spar attached, now to work on making some ribs for the trailing edge and Anti servo tab.

  Jun 16, 2023     Aileron control cables fabricated - (16 hours)       Category: Controls

Started working on the aileron cables several months ago. First order was creating the non standard routing for the cables, as I am using a fabricated control yoke. Once the installation of the pulleys (not final, just for fabrication purposes) was completed, I began to fabricate the cables. Getting turnbuckles was a challenge, but I did eventually find some. The fabrication of the cables was straightforward. The only challenge was the pass through from the aileron bellcrank to the return line under the passenger seat. It is very close, and the hardware from the cable is close to contacting the structure. This is only at the extreme deflection, that will most likely not be achieved when the ailerons are installed. Adjustments will be necessary with the final rigging.

  Jun 16, 2023     Rudder and control connection - (16 hours)       Category: Tail Feathers

I've been behind on documenting the work done. I completed the structure of the tail feathers, and purchased a bellcrank for the rudder. Connected it to the base of the rudder per plans and began the fabrication of the rudder control bellcrank and the push rod that connects the bellcrank to the rudder. Original location for the rudder bellcrank is much lower, but this location required bending the rudder push rod and was not satisfactory. I moved the location of the bellcrank up higher in the empennage, and was able to use a straight control rod w/ greater success. I have tested the set up and I get a full 25deg deflection on both sides as called for in the plans. I will disassemble paint and bolt all parts in place as per plans.

  May 15, 2023     Brief update Category: Empennage

Just a brief update. Rudder is clecoed in place, rudder pedals connected. Starting to work on the cable controls to the ailerons.

  Jan 05, 2023     Continued work on Vertical Stabilizer and Rudder - (16 hours)       Category: Empennage

I have continued working on the rudder and the Vertical stabilizer. There are actually 3 sections to work on, the forward piece of the vertical stabilizer, the middle flat pieces that fit under the forward piece and attach between the 2 vertrical spars, and finally the rudder itself. The rudder is attached via a piano hinge on the starboard side of the aft spar. The bottom is cut inline with the bottom of the vertical stabilzier, and the top supports the counterweight that extends from the top of the rudder forward over the hinge line toward the front of the stabilizer. So, here's where I had to re-do the top of the rudder. The bottom of the rudder needed to be cut on an angle, but matching the top surface of the aft fuselage and the bottom of the vertical stabilizer. I cut it at a wrong angle. When I realized my mistake, I devised a plan to lower the rudder, re-cut the bottom angle, and add a small section to the top of the rudder. I bent another piece of aluminum, fit it on top of the rudder, riveted it in place and attached the rib and the counter weight to the top. Worked like a charm. I will monitor for any problems during flight testing. See pictures for details.

  Dec 16, 2022     Ongoing work on Rudder and Vertical Stabilizer - (8 hours)       Category: Empennage

Working on Rudder. I have finished the internal ribs and had to manufacture the upper support for the counterweight and the lower bracing for the rudder horn. The part I had purchased was for an older version that housed the counterweight internally in the tail cone. Pretty, but it interfered with the rudder, trim, and the pulleys that will control the tailwheel. The new version places the counterweight on topof the rudder, extending out over the vertical stabilizer. To put this all in place and ensure the parts don't interfere, it's necessary to fabricate and fit the vertical stabilzer. This is a 2 part piece of sheet metal. The forward piece was previously bent and required fitting and cutting to it's final form. Once cut, it is held in place with clamps. 3 internal ribs are attached to the forward Vert spar and provide structure to the forward part of the stabilizer. The middle part is supported by ribs and the forward and rear stabilizer spar. The rudder attaches to the rear spar and is positioned to ensure the upper counterweight is level and has plenty of clearance. Lots of fitting and cutting. Thanks to Evan for helping me draw the rough lines to get the 4 angles and bend of the forward piece set up.

  Dec 09, 2022     Rudder time - (8 hours)       Category: Empennage

I've been working on the control cables and bellcranks. I have the Control Yoke installed, the elevator push pull tubes connected and made the rudder cables.
I was going to start on the aileron cables, but didn't have the proper parts for the turnbuckle, and after ordering, I decided to start work on the Rudder. The kit I purchased was originally delivered in 1970 and has old parts and some new ones. The rudder spars included the small rudder and large. As I am building a taildragger, I want as much slow speed rudder authority as possible. Therefore I went with the full sized rudder. The modern plans call for a 2 piece rudder skin. I had a one piece bent to spec skin and thanked the homebuilding gods and proceeded to sort through my parts to find the proper forward and aft spars. I found what I wanted and moved on to fabricating the internal ribs for the rudder. The current plans are for the 2 piece skins, so I had to improvise and make some measurements, customize the ribs, cut wooden formers, cut the rib blanks, clamp everything together and bang out the ribs. Worked surprisingly well. I now have three ribs that will reside inside my rudder, offering support and rigidity. After this, I found the forward and rear spars for the vertical stabilizer and spent the next 2 hours trying to figure out how to ensure they were upright, centered, and square. Mission accomplished and I mocked up the rudder to the rear spar. Next task will be working with Levil aviation and coming up with a plan for their rudder trim.

  Nov 20, 2022     Final layout of Control column base - (8 hours)       Category: Controls

Working in the Garage this weekend. I had mocked up the location of the control column and the location for the pulleys that will transfer the motion of the turn on the yoke to the up and down needed for the ailerons. I installed nutplates to allow for the complete removal of the control yoke. I have installed it in it's permanent configuration. I will be removing it several times as I install other components and riveting in the floor, rudder pedal support, firewall, brakes, and other support structures in the instrument panel area.

  Nov 02, 2022     Control construction update - (40 hours) Category: Controls

I have been working on several components of the control system. There are 3 Major components: Aileron controls via the control yoke, Elevator controls also with the control Yoke and the Rudder controls via rudder pedals. I will discuss the progress of each of these areas.

Aileron: I have completed the fabrication of the core elements of the cable system located horizontally in the cockpit. These consist of the control yoke, pulleys that take the control cable from the yoke to the base pulley, through the landing gear box, outward to the sides, back to the lower aileron bellcrank, then back to the connecting return to the other side. Pulley mounts and brackets have been held in place with clecos. Only cable guards on each pulley need to be made with the control cables.

Elevator: A bracket was welded to connect the forward elevator tube to the control yoke. This bracket was required to lower the angle of the tube. The aft portion is connected to a "swing" to transfer the for and aft motion toward the rear of the aircraft. Brackets and bracing hold the "swing" in place, The Forward and the portion of the aft tube in the passenger compartment will be eventually covered by a tunnel fabricated from sheet aluminum. This will also form an armrest and center console for gauges and engine controls.

Rudder: Cables attatch to the inner portion of the rudder pedals adjacent to the control column. The cables will travel inside the tunnel under the swing and to the aft of the fuselage. A rudder bellcrank has been fabricated and secured to the rear of the fuselage. The cables are guided to the rear by micarta guides and connect to the rudder via a control rod attached to the rudder bellcrank.

  Jul 12, 2022     Aileron control cable routing - (4 hours)       Category: Controls

Control column connection to aileron cables. Locating the pulleys at the base of the column was not obvious to me, but as soon as it was placed, the routing became obvious. I will use yellow mason line to visualize the route for the cables, through the landing gear box, out to the sides of the fuselage and to the lower aileron bellcrank that will move the aileron control rod to push the upper aileron bellcrank.

  Jul 12, 2022     Horizontal Stabilizer Bracket - (16 hours)       Category: Controls

I have fabricated the bracket that attaches the Horizontal Stabilizer to the fuselage. I originally started with a flat piece of 0.040 plate, progressively bent it into a half circle with flanges at each long edge. It was very difficult to get the multiple bends square and ultimately it yeilded a substandard part. I then went to the auto parts store and bought the appropriately sized exhaust pipe, cut it slightly longer than in half, welded the brackets to it and then bent up the edges to create the flat flanges for attatching to the spar of the HS. The first try using the TIG welder ended poorly as I burned through each piece of metal and appliied too much heat, warping each part. I then turned to my flux core wire fed welder and had much better success. I was able to acheive full penetration and a very secure attachment of brackets and tabs. Heat was controlled and the part fit. I found some adjustments were necessary, but I have secure and free movement.

  Jun 06, 2022     Main photo       Category: Tools

Updating my Project photo

  Jun 06, 2022     Tig Welding! - (8 hours) Category: Tools

I have purchased a Prime Weld 225x tig welder with the intention of teaching myself to weld and fabricating parts myself. I have 4 types of metal to put to put together: Aluminum, Stainless, Inconel, and Chromemoly. I started with Aluminum and have been at it for about 4 hours. I've burned through alot of coupons, but I feel comfortable holding the torch and making a good puddle. Now I have to get the hang of introducing filler and working a good rhythm. I plan on making most of my welded parts including the tailwheel support, aileron brackets, engine mount, exhaust, and other incidentals.

  May 02, 2022     Drawing control system routing - (2 hours)       Category: Controls

Control yoke has been located in forward fuselage along with rudder pedals. Now it is time to plan routing of aileron and rudder cables as well as the pushrod that will control the horizontal stabilator.

Aileron: I have modified the routing due to the use of my control yoke mounted near the firewall forward of the Landing Gear Main (LGM) box. There are two pulleys mounted at the base of the yoke, directing the control wires forward to the base of the forward side of the LGM. Two pulleys there send the wires through the LGM to the aft side, where two more pulleys direct the wires out to the sides of the C-channel. Two additional pulleys direct the wires aft, to the corner posts, at the base of which will be a bellcrank directing the forces upward via a pair of control rods to the Aileron belcrank. A connecting wire will continue aft from the lower bellcrank, turn inward by a final pulley to close the loop. A turnbuckle will be placed between the 2 aft pulleys to adjust tension.

For the rudder control, the cable will attach to control arms on each rudder pedal assembly. These are outside the control yoke base, approximately 6 inches apart. They will be routed to the base of the forward side of the LGM and using pulleys will be sent to the rear of the LGM. Pulleys there will direct them toward the center approximately 2 inches apart. The cables will continue rearward and to another set of pulleys that will direct them upward along the bottom of the empanage to the Rudder Bellcrank. Here they will control the rudder as well as the tail wheel.

Horizontal Stabilator: This is manipulated by a control rod from the mid point on the control yoke shaft. The shaft is angled downward to run along the top of the LGM and aft toward a bellcrank within the center tunnel between the passenger seats. From the bellcrank, another control rod will connect to the Horizontal stabilator bellcrank at the rear of the fuselage.

Preliminary measurements and locating the pulleys will be done prior to making the bellcrank and pulley brackets. The bellcranks are weldments that will be produced later.

  Mar 01, 2022     Control Yokes, brackets and brakes - (20 hours)       Category: Interior Finish

Istalled the seat supports. Working on installing the control yoke. Bracket and base plate held in with clecos. Rudder pedals installed on their brackets. Used brackets, pedals, welded bars from a Grumman Tiger. All fits together like a charm. Pedal and brake acuators required clearancing to get full motion. At this time will only have brakes on pilot side. May consider slave cylinders later. See pics for details.

  Dec 27, 2021     Seat supports, seat adjusters and boat seats. - (24 hours) Category: Interior Finish

I have been following other BD-4 builders and their seat mounting schemes...the plans call for a short length of tubing with 2 tabs welded to the back and attached to the side of the C-channel. A slot is cut in the front halfway down the length of the tube. Another smaller piece of tubing is welded to the end of a pipe that runs the width of the cockpit. The seat rails sit on these two pieces of tubing and the seats sit on top of these. I have used 2 boat seats attached to 0.125 steel plate that have adjustable rails attached. I will get 7" of movement out of these seats. Cutting the individual pieces, deburring, welding, placing and ensuring the assembly is square and removable has taken considerable time. Here are a few pictures.

  Nov 23, 2021     EIS screen creation - (12 hours)       Category: Avionics

I've used the Megasquirt EMS computer for years in my Jeep and have a good understanding of it's capabilities. With my Mazda Rotary 20b engine I'll be running 3 rotors, 6 fuel injectors, 6 ignition circuits, fuel pump, water pump, and 12 monitoring channels. I will be able to log and tune all from a raspberry Pi computer located in the dash. I'm currently doing all of this in my Jeep, and have decided to design a custom dashboard with TunerStudio software. Here's a pic of what I have so far.

  Nov 23, 2021     More work on landing gear - (6 hours)       Category: Landing Gear

Working on the landing gear. Re making some of the support brackets and bolting everything together. Although it will be a chore, removal will be possible in the future. I've had a suggestion to create a owners repair manual to provide future owners instructions on how to repair and replace parts. Maybe something for the future.

  Sep 24, 2021     Starboard Landing Gear - (4 hours)       Category: Landing Gear

Working on the openings in the floor for the landing gear. Using the finger sander to clean up the opening. Working on the brackets that hold the LGM in place. Match drilled the holes and test fit the gear in the box. I'm using gear out of a Cheeta and was concerned about the clearance. With the wheels and tires I'll be using, there will be no issues.

  Jun 18, 2021     Back at it... - (4 hours)       Category: Fuselage

Spent some time today cleaning up the fuselage, replacing some bolts I removed when I installed the landing gear box, and making some of the brackets for mounting the gear legs. Ordering some more angle aluminum.

  Jun 17, 2021     Look what I bought! Category: Engine

I have been planning on using a Mazda rotary engine for my project. I have researched the issues associated and decided to proceed along this path. Originally I planned on using a 1.3L, twin rotor turbocharged engine with a planned take off output of 200hp, Cruise HP of 150 and use the turbocharger to normalize up to 13000'. My goals include a cruise of approximately 175 MPH at altitude. I have already purchased an engine and planned on a rebuild. I have secured a planetary based PSRU built specifically for the rotary engine and was not looking to begin work on the engine program until after the flying surfaces had been built.
Well....while looking on one of the mail lists I follow, I saw a gentleman selling a Mazda 20b 3 rotor engine. This particular one was turbocharged, and came with a brand new IvoProp controllable propeller, a Marcotte 2.4:1 PSRU and many other assorted parts. The asking price was $4,000 for the lot. I pulled the trigger, made the deal, and drove out to Austin, Texas to pick it up. This will require a rethink on what my goals are as this engine should make approximately 240 HP naturally aspirated. I will certainly use all of it during takeoff, and then be able to use 200 HP during cruise up to 13,000'. I will need to ensure my radiator as well as my support structure is up to the task, but I think I got a steal! Pictures to follow.

  Feb 04, 2021     Keeping in touch.... Category: Workshop

No work done lately...covid has my full attention for now. When the hospital slows down, I'll be back at it!

  Nov 25, 2020     Surgery, recovery and research - (1 hour) Category: Workshop

Not much going on at the aircraft factory right now. I've had cervical spine surgery, and have been on lifting limitations. Working extra hours at the hospital. I'll be back in the saddle again soon.

  Sep 01, 2020     Cleaning up Category: Workshop

I haven't done much in the last month due to an injury. Keeping the shop clean has been my priority. Lots of online research.

  Jun 18, 2020     Making Airplane Noises - (8 hours)       Category: Interior Finish

Early on in my planning, I was made aware of a gentleman who was selling a yoke assembly that he had removed from his BD-4 project. Intending on using a yoke on my project, I purchased it long before I had acquired my kit. I am now mocking up the cockpit, seating, landing gear and rudder pedals and placed some items temporarily in place to get an idea of how the pilot (me) will fit inside all of this. Here are few pictures. Overall, I think this will work comfortably.

  May 19, 2020     Seats - (6 hours)       Category: Interior Finish

I wanted to have automotive seats in my airplane, planning on 3-4 hour flights, I found a seller on Facebook Marketplace and bought a couple of seats out of a Nissan Juke. Initially, they felt heavier than I thought I wanted to use. There were explosive air bags, steel brackets, sliders, head rests, and height adjusters that weren't going to be used in my project. Pre-surgery weight 71 lbs each. Post surgery-35 lbs. I was able to retain the back adjuster. I ordered some low profile, light weight seat adjusters from a speed shop. I'm creating brackets to set the heights above the landing gear, I needed to start making choices about seat placement, installation of control yoke, rear seat supports and more. All before I install the exterior floor and begin the installation of the landing gear.

  Apr 18, 2020     Weekend Work - (1.5 hours)       Category: Fuselage

Making a part and reviewing the plans. Needed some 1"" extruded angle and placed an order to Aircraft Spruce. Pulled out all my raw materials, separated everything per material-Steel, Aluminum, Fiberglass. I think I almost have enough parts to build another whole airplane. Hmmmmm...
Today I made part BD-4-1-07...an angle for the wing that helps tie the spar to the fuselage. The previous builder had placed one on the port side, but not the starboard. There are also several holes left to drill that require a 12 inch drill bit extension. Onward to Harbor Freight!

  Apr 12, 2020     Working through the plans/assembly drawings - (8 hours)       Category: Fuselage

This project was started in the early 1970's and sat for a long time. After I completed the stretch and attached the rear fuselage, I have started going through the assembly drawings step by step to accomplish 2 things. 1. Make sure there are no omissions. 2. To make updates and changes since the last builder had his hands on the project.

Today it was working on the firewall. Adding gussets and bracing per plans. There were some angles omitted, some gussets to add. Fun work! Here are the end results:

  Mar 24, 2020     Completion of fuselage extension - (24 hours)       Category: Fuselage

Completed the fuselage extension for my project. A fuselage extension has been required to balance heavier engines including the Mazda Rotary I plan on using. Although the engine will weigh only a few pounds more than a comparable Lycoming, I plan on adding turbo normalizing, intercoolers, and oil coolers in the engine compartment and a P-51 style radiator at or near the CG under the plane as well as an effective muffler system to keep it all quiet.

The fuselage extension was 18 inches and made of 1 1/2 inch angles as the primary load structure, 1 inch cross bracing angles and gussets made out of .063 2024 T3 aluminum plate. I used the general plans from Ray Ward's drawings that he used to counterbalance his Chevy 454 installation, but had to custom make each piece to ensure the angles and the gussets were strong enough for the job. I also dropped 2 plumb bobs, and ran a center string to keep it all straight. I feel confident that I'm straight and strong.

  Feb 25, 2020     Continuing with fuselage extension - (2 hours)       Category: Fuselage

Continuing with the fuselage extension. Measured, cut, fit and secured bottom longeron on both port and starboard sides. The fuselage is measured and squared. Plumb bob lines dropped from front, middle and aft section of plane. Alignment of fuselage was verified and fuselage secured to work table to allow for construction of other longerons. Measurements taken and mid frame longeron cut and fit into place. Gusset made, and using clecos, attached to fuselage.

  Feb 22, 2020     Extending the fuselage - (2 hours)       Category: Fuselage

Today I began work on setting up the fuselage to extend it by 18 inches. This length will allow me to accomplish 3 things. One, create more back seat room for passengers and cargo. Second, it will allow for more back seat leg room in the event I actually carry 4 adults at one time. Third, it will help balance a slightly heavier power-plant as I plan on using a turbo-normalized Mazda Rotary engine.

I secured the fuselage to the table to ensure there won't be any movement while I work on it. At this stage, it is very light weight and easily moved. I then lined up the tail section and set my distances. I plan on using a simple extension without modification of either the fuselage or the tail section. This will give me a flat section over the back seat, providing more headroom and making this a much easier project than removing and replacing the existing longerons.

Then using a straight edge, I set my distances between the fuselage and empenage to 18 inches. Tomorrow I will drop some plumb bobs to establish an exact center line. Then I can measure and cut 6 longerons to fill the space. Afterward will be the gussets and finally the cross braces.

  Feb 08, 2020     Beginning the cleanup - (2 hours)       Category: Fuselage

Down in the garage today I laid hands of the fuselage for the first time. I've reviewed the plans several times, and it's time for me to start making parts. But first I had to get 30 years worth of corrosion off the fuselage. It's actually in really good shape. All the hardware is solid, and without anything more than some surface corrosion. The angle and C channels are all intact. All they needed was a good scrubbing. Out came the 3M scotch pads and the scrubbing began. The fuselage is incomplete, and will need gussets as well as some angles to complete the cage. Then I will need to build the 18"" extension to the fuselage before I attach the empenage and begin working on the control surfaces and wings. Here's some pictures of the progress.

  Jan 06, 2020     Making airplane noises       Category: Research

I've got my fuselage on a work table, and for visual effect I've attached the tail section for a sense of size. I had also purchased the assembly instructions for the current version of the BD-4. The dimensions have changed, but I am more interested in the structural updates that have occurred. They are a very simple bunch of large drawings, with each page marked in step by step fashion. Parts that have to be made are blueprinted out. There are some weldments that I will be purchasing. I have also recently found some used parts on E Bay, including wheel/axle brackets for my previously purchased s-ply gear legs.

Today's research included finding sources for engine parts and reviewing the plans to extend the fuselage 18 inches. This is a common upgrade to balance out heavier engine installations as well as create more back seat room. While the plane is a 4 passenger, I will be using it more in the 2+2 configuration the majority of the time.

I also had fun looking through the boxes of parts finding many things I won't have to purchase separately. Soon to inventory and catalog

  Nov 07, 2019     More Wings - (2 hours) Category: Wings

Spent the afternoon studying the plans and cutting down the rest of my wing ribs. For those that don't know, the BD-4 had a unique wing building technique. A tubular spar was carried through the cabin, and 10 feet out each side. Wing buckets were then slid over the spar, glued together and secured to the wing. These formed the fuel tanks when sealed, and the structure of the wings. Unfortunately, as all wing tanks will do, leaks occurred. This created problems as you might imagine. It was discovered that the wing tank sealant was very effective as long as it was kept wet by the fuel it was sealing in. If it was allowed to dry due to low fuel levels, maintenance, inactivity-leaks would occur. The BD-4 factory answer is to use aluminum honeycomb panels, cut to shape as wing ribs, slide these over the spar, glue into place, and to wrap aluminum sheet to create the airfoil shape. The aluminum sheet is adhered to the honeycomb panels with Pro-seal. This also serves to seal the bays that are used for fuel. The honeycomb panels are expensive, and I already had perfectly formed ribs available to me. My plan is to use the cut down panels as wing ribs, adhere them to the spar, then wrap the wing and adhere it to the ribs with pro-seal. The rest of the wing will be built to plan.

  Oct 06, 2019     Cutting down Wing Panels to make Ribs - (2.0 hours)       Category: Wings

I have been thinking for a long time on how to maximize my usage of the materials I obtained with my purchase of the uncompleted BD-4 kit. So, today I made a decision regarding the wing ""Buckets"" and how I would use them. I want to build metal wings, because I did not want to rely on the buckets to maintain the airfoil shape or hold fuel on an ongoing basis. BD-4's are famous for their leaking wings, and I was wanting to avoid this sort of infamy.

I decided to build a hybrid wing. I will use the wing buckets as the rib, cutting off the panel parts. I will secure the remaining rib to the spar, sealing it as called for in the plans. I will then place aluminum skin over wing ribs, using Pro-seal to adhere them as in the current plans. This will yield a very strong and light wing, and will hold the required 50 gallons of fuel and remain leak free. Later entries will describe sealing the wing tanks and using Pro-seal to make them leak free.

  Sep 09, 2019     It's all mine!       Category: Research

I have returned with one partially assembled BD-4! 30 hours of driving and 8 hours crawling around in an old garage loading up the kit. Much more complete than I thought it would be. Many usable parts here. The fuselage and empenage look to be in good shape. Landing gear, hardware, weldments, raw aluminum... I have to inventory and budget for everything else. Fun times!

  Sep 03, 2019     Saw horses! - (2 hours)       Category: Workshop

Sawhorses!
Good morning! I'm leaving Friday to pick up my airplane project. I'm going to need a sturdy table to work on. I found a set of instructions to build some ridiculously simple sawhorses. These will form the base of the table with 4x4 square sheets of plywood. I will have a 4 or 8 foot table to work on as needed. Here's how I did it....

One pair of sawhorses requires 5-2x4's, 8 feet long. Measure each board to make 3 pieces approximately 32"" long. Cut on the line you mark, and the kerf of the saw blade will allow for each piece to be equal in size.

Make the ""I"" beam first. Mark the center of one of the pieces at each end. Center another piece on edge on this mark. Clamp and use 3"" screws to hold the piece on edge securely to the bottom piece. Mark the center on the ends of another piece, line this up on the exposed edge, and screw in place. It is important the middle piece is centered, as this sets the angle for the legs. Attach the legs to the ""I"" beam as seen in the pictures. The legs go under the the lip of the top part of the ""I"" beam, and rest on the lower part. Use 4 screws to secure each leg to the ""I"" beam.

That's it! Total cost was $19 for three sawhorses and they stack together easily. I will use plywood or particle board for the table top when needed. Feel free to comment or ask questions!

  Aug 28, 2019     And so it begins.....       Category: Research

Hello all! I'm Les Criscillo, a Registered Nurse living in West Central Florida. I have had a passion for aviation since I was very young. I obtained my private pilots licensure in 1986 and have been flying since then. In the 1990's I built a KR-2 experimental airplane and this week I will embark on a much larger and more complicated project The Bede Aerospace BD-4. This plane was designed by James Bede in the 1960's and hundreds have been built around the world since then. I had several design requirements as I was looking for suitable projects to consider.



Cross country capable: I live in a beautiful state and want to be able to travel to any beach within 3 hours. That requires 150 mph and a 4 hour fuel capacity.
Simple metal construction: I have worked with wood and fiberglass before, and in Florida, the elements are hard on both of these materials. I plan on outdoor storage and required a material that would hold up to our heat and humidity.
Automotive engine appropriate: The minimum requirements are for a 160 hp engine to power this aircraft. I have been working on and building engines for over 30 years. I am aware of their limitations in aircraft, and their capabilities. I am going to power mine with a Mazda rotary 13b engine. This engine's design is inherently safe for aircraft operation, and with appropriate development of the support systems, will provide safe and powerful propulsion for many years. Mazda rotary engines have been built since the 1960's and have only 3 moving parts! Smooth, powerful and small, this engine will be an exciting part of this project.
Roomy. I wanted to carry two passengers with cargo space for camping, luggage or two passengers depending on the mission of the day.
The BD-4 meets all of these requirements. There are others that meet them also, but the last requirement I have is always what brings me back to the BD-4. Affordability. Out the door, I should complete this project for less than $30,000. A basic VFR aircraft, with new instrumentation, a zero timed engine, and more than enough capability.



I will leave in 9 days to pick up my project and bring it back to Florida. I will post here regularly to document this project, receive advice and hopefully some encouragement as well. Wish me well!