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.

  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.