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.

  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.

  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.