Project: Serg   -  
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Builder Name:Sergio Desiati   -  
Project:   Bearhawk - Patrol   -   VIEW REPORTS
Total Hours:285.2
Start/Last Date:Aug 31, 2019 - No Finish Date
 
Friendly URL: https://eaabuilderslog.org?s=Serg

Home or Last Project Picture

May 24, 2020     Flap controls - (3.7 hours)       Category: Wings
Replaced all flap hardware with drilled bolts, and castellated nuts. Clearanced flap cables and fittings in wing root; all very close as per plan, but adequate clearance! Pretty happy with that. I also fitted the left wing aileron and flap bearings... five less small loose parts!

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May 11, 2020     Aileron/flap hinges - (1.7 hours)       Category: Wings
Installed right hand side hinge bearings. Started fitting right hand side aileron hinge brackets.

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May 09, 2020     Windshield - (3 hours) Category: Fuselage
Trimmed upper forward skylight/windshield former, trimmed windshield edges to match, bodywork on windshield fiberglass faring.
Also replaced some small aileron linkage hardware.
 
May 09, 2020     Windshield - (3 hours) Category: Fuselage
Trimmed upper forward skylight/windshield former, trimmed windshield edges to match, bodywork on windshield fiberglass faring.
Also replaced some small aileron linkage hardware.
 
 
May 06, 2020     Skylight - (.9 hour) Category: Fuselage
Fitted skylight center support. Short day today.
 
May 04, 2020     Skylight - (3.7 hours)       Category: Fuselage
Fitted and installed aft skylight former, and dorsal stringer.

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May 01, 2020     Window frames - (3 hours)       Category: Fuselage
Finished right hand side window. Everything fits perfectly; very happy! In one of the pics, you can see an early panel mockup... it's nice to start visualizing, but I've got a ways to go before any of that gets really considered. Skylight is next!

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Apr 29, 2020     Window frames - (3.2 hours)       Category: Fuselage
Fitted right side window sheet metal and clecoed to tubing. Acrylic cut to size. I need to finish fitting angle backing, then I can drill acrylic for bolts. Getting there!

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Apr 28, 2020     Side windows - (3.3 hours)       Category: Fuselage
Today I finished the left window; all parts are ready for interior paint, and final assembly. I also swaged the two flap cables where they attach to the control horn in the wing root. This is going to need a little more work for clearance, but all seems to work very well. Right window next!

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Apr 27, 2020     Side windows - (4.3 hours)       Category: Fuselage
Today I finished trimming the left window sheet-metal. Clecoed everything in place, and it looks perfect; very happy with the fit. Next I'll have to work on the sheet metal retainers that go on the inside, as well as the nuts and bolts that sandwich all the sheet-metal and the plexiglass together. Also trimmed right side acrylic to size.

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Apr 25, 2020     Side windows - (3.3 hours)       Category: Fuselage
I cut the left-hand side plexiglass to fit in window frame. Fitted and trimmed all aluminum window frame parts. Fasteners next!

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Apr 24, 2020     Aileron cables - (.5 hour)       Category: Wings
Installed aileron cable pulley guards... and the pictures I promised of the finished aileron and flap control sistems.

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Apr 23, 2020     Flap/aileron controls - (3.2 hours) Category: Wings
Cut extra clearance in right wing ribs for aileron on crossover cable. Installed correct hardware for aileron pulleys and bellcranks. Aligned and drilled flap torque tube; installed all bolts and springs... all looks great and in perfect alignment. All I have left to do is attach the cables coming from the fuselage, but I need to get more swaging supplies.
 
Apr 22, 2020     Aileron controls - (5.8 hours) Category: Wings
Fabricated all aileron cables; staged all terminations and checked with go/no-go gauge. Pulled some tension and all works as it should. The crossover cable still rubs some of the ribs; that will be addressed tomorrow... lots of pictures to follow.
 
Apr 21, 2020     Aileron controls - (2.8 hours) Category: Wings
Installed aileron pulleys and bellcranks. Began running cables from control stick to aileron bellcranks.
 
Apr 21, 2020     Aileron controls - (2.8 hours) Category: Wings
Installed aileron pulleys and bellcranks. Began running cables from control stick to aileron bellcranks.
 
Apr 20, 2020     Wing hardware - (1.5 hours)       Category: Wings
Checked all wing hardware for spec; I had to replace just a few washers here and there, to get the required threads showing beyond locknuts. Torqued everything, and applied
Viz Torque.

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Apr 19, 2020     Cables - (1.4 hours) Category: Wings
Fitted aileron bellcrank bearings; cut and swaged flap cables from Y split to wing control arms.
 
Apr 18, 2020     Opened wings - (1.8 hours)       Category: Wings
Opened wings, removed and inventoried all parts, cleaned/dusted inside wings, and clecoed them shut. I have a good amount of reading to do before I start work here.

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Apr 17, 2020     Various - (2.7 hours)       Category: Fuselage
I cut up some rubber tubing to be used as a bushing, where the winshield gets bolted to the airframe... a little extra insurance against cracks. Installed windshield and all trim pieces with screws for the first time. All fits perfectly. Oh yeah, more bodywork to the fiberglass trim! Took some time with a couple more nutplates and some other cleanup to the lower bootcowl.

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Apr 16, 2020     Windshield - (2.6 hours) Category: Fuselage
Drilled fiberglass skirt and installed nut plates on boot cowl.
 
Apr 14, 2020     Windshield - (6.5 hours)       Category: Fuselage
Today I had to remake the formers that the windshield bolts to; The ones that were provided with the kit, were too narrow at the bottom... the new ones match the external aluminum trim pieces that will sandwich the windshield. I installed nut plates on the formers and temporarily installed the windshield. Everything seems to align perfectly. In the next session, I will bolt the fiberglass trim piece to the boot cowl, thus finishing this process.

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Apr 13, 2020     Windshield - (2.3 hours)       Category: Fuselage
Removed fiberglass trim piece from fuselage/mold; I'm glad I used a bunch of automotive wax as a release agent, because it separated very easily. Fiberglass trim piece was cut to size, and sanded. I still need to do a bunch of putty work, but the initial part looks exceptionally nice. Success!

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Apr 12, 2020     Windshield - (2.7 hours)       Category: Fuselage
Laid up 9 layers of glass using Westsystem 105, for the windshield trim. Made a mess everywhere, but the trim piece looks really good, with no bubbles! We shall see once it's dry tomorrow... lots of sanding next.

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Apr 11, 2020     Windshield - (1.8 hours)       Category: Fuselage
Finished applying electrical tape to windshield and boot cowl interface. This tape will hopefully keep the fiberglass from sticking to either surface, as well as providing a smooth transition for the glass to lay into. We shall see... I also cut the fiberglass in properly sized strips.

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Apr 10, 2020     Windshield - (2 hours) Category: Fuselage
Fitted side metal strips on windshield; also started taping exterior transition in preparation for fiberglass.
 
Apr 08, 2020     Windshield - (5 hours)       Category: Fuselage
More windshield fitting today. I followed some wise advice of another Bearhawk builder; take a little bit off at a time! I'm really happy with the fit. I also had to redo the aluminum standoffs that go behind the front lower edge of the windshield. The original ones were too thin, and they didn't follow the curvature of the boot cowl very well. These new ones fit perfectly, and are made of .032"".

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Apr 06, 2020     Windshield - (2.3 hours)       Category: Fuselage
Today I started fitting the windshield; all is good so far, with only some minor trimming left. They also fabricated some aluminum standoffs that will go on top of the boot cowl, behind the windshield, to support it.

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Apr 05, 2020     Brake lines - (2.1 hours)       Category: Landing Gear
Upper brake lines installed; they are just sitting inside the boot cowl for now... the next time I take it apart, I will secure the lines and install parking brake valve. I also prepared some parts for the windshield installation.

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Apr 04, 2020     Brake lines - (1.7 hours)       Category: Landing Gear
Installed 36��braided ��ircraft specialty��brake lines in gear legs. All looks great.

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Apr 03, 2020     Hung wings! - (3.5 hours)       Category: Fuselage
Today was a very busy day; after taking a bunch of measurements, I completely rearranged the garage... I was able to get the airplane to fit sideways and have enough room left over to hang the wings. That I did! This way, I can properly fit the windscreen, without those silly plywood jigs I made.

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Apr 02, 2020     Windscreen - (1.5 hours)       Category: Fuselage
Today I finished the wing root templates; they seem to fit well; I do have to take a bunch of measurements to make sure... before I start cutting/fitting the windscreen!

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Apr 01, 2020     Windscreen - (1 hour) Category: Fuselage
Started making wing root templates for windscreen fitment.
 
Mar 28, 2020     More deburring!! - (2.5 hours) Category: Fuselage
Today I finished deburring all floor panels as well as the gear leg fairings.
 
Mar 26, 2020     Deburring all sheet metal - (2.5 hours)       Category: Fuselage
More deburring today... cargo door, and a couple floor pieces. I also fitted the forward skylight former/bulkhead. I called Mark to order the rear former, because it was omitted from the kit. That process will be on hold for a bit.

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Mar 25, 2020     Boot cowl - (2 hours)       Category: Fuselage
Finished deburring all boot cowl sheetmetal. Also finished fastening and isolating all four fuel lines... I ended up using rubber hose in the points where the fuel lines touch the fuselage tubing, and fastening it with nylon cable wrap. Very strong and tidy.

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Mar 24, 2020     Fuel lines - (2.5 hours)       Category: Fuselage
Since I removed the boot cowl to clean up some minor areas, as well as deburring the entire thing... I wanted to put some effort in fastening as well as vibration dampening the fuel lines. I have a little bit more work to do in all those regards, but it's looking pretty good!

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Mar 22, 2020     Boot cowl - (2 hours)       Category: Fuselage
The lower boot cowl/landing gear strut interface needed some improvement... I enlarged and cleaned up the gear strut holes in the boot cowl. As a result, I had to move around a couple nut plates that hold the aft portion of the lower boot cowl. I really like how it turned out; I'll need to install a rubber seal next.

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Mar 21, 2020     Front door - (1.5 hours)       Category: Fuselage
I finished fitting the front door sheet metal, to incorporate an armrest on the upper surface. I had to go borrow a 48 inch brake to put two 90�ngles in the aluminum. I am very happy with the outcome; looks and feels good!

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Mar 21, 2020     Front door - (1.5 hours) Category: Fuselage
I finished fitting the front door sheet metal, to incorporate an armrest on the upper surface. I had to go borrow a 48 inch brake to put two 90�ngles in the aluminum. I am very happy with the outcome.
 
Mar 20, 2020     Rear window C frame - (2.5 hours)       Category: Fuselage
Left-hand side window C frame shimmed out .032. I also cleaned up the cargo wall opposite of the door; added a few more screws, rounded the sheet metal at the front, and added an Adell clamp for support. I also started redoing the main door sheet metal for a better fit.

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Mar 15, 2020     Window C frame - (1.1 hours)       Category: Fuselage
Finished shimming out the right hand side window C frame. I bought some cheap plexiglass from Lowe's so I could play with the fit as well as practice drilling it. No issues! Ordered some UV block/tinted Plexiglas.

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Mar 14, 2020     Cargo wall and C windows - (3.8 hours)       Category: Fuselage
Built up a cargo wall (opposite of the door)... this will keep sharp/heavy objects from contacting the fabric and damaging it. I also started taking the C windows apart, since they didn't have enough space in their groove for both Plexiglas and the glued fabric. Seems like adding an .032 spacer will allow clearance for everything.

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Mar 10, 2020     Window frames - (2.1 hours) Category: Fuselage
Had a good study session with the plans/manual today... all makes sense now! Started fitting all the different sheet/angle parts to the window frames; I will have to order some acrylic before moving on much farther.
 
Mar 08, 2020     Door skins - (2.5 hours)       Category: Fuselage
Finished skinning front door, installed latch on cargo door. Very happy with the fit.

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Feb 28, 2020     Main door - (2.5 hours) Category: Fuselage
Started fitting main cabin door sheetmetal. Good progress, but will need much more work for a perfect fit.
 
Feb 24, 2020     Baggage door - (2.5 hours)       Category: Fuselage
Fitted and installed baggage door skin. Aligned and drilled for the latch. I need to go source the correct spring so I can finish the latching mechanism... main cabin door is the next step.

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Feb 03, 2020     Various sheet metal trim pieces - (3.4 hours)       Category: Fuselage
Built up and formed tail hinge covers; these are the pieces the fabric will stick to around all the control surface hinges. Also formed aft window cover pieces.

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Feb 02, 2020     Gear leg fairings - (2 hours)       Category: Landing Gear
Well, third time is the charm for the left gear fairing. Good result this tome. I also fastened the aft portion on both sides.

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Jan 31, 2020     Gear leg fairings - (3.6 hours)       Category: Landing Gear
Back to the drawing board for the gear leg fairings. Cut narrower ones out, and they fit much better. Since I got so good at installing nut plates, I installed 20 more for the gear leg fairings.

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Jan 27, 2020     Gear leg fairings - (2 hours) Category: Landing Gear
Started working on the gear leg fairings.
 
Jan 26, 2020     Rudder cables - (2.3 hours)       Category: Controls
Installed rudder cables and turnbuckles. All good!

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Jan 23, 2020     Boot cowl - (2.8 hours)       Category: Fuselage
Finished boot cowl today at last! I am extremely satisfied with the result.

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Jan 22, 2020     Boot cowl - (5.5 hours)       Category: Fuselage
More nut plates today; surprise surprise! Also installed door/windowsills, firewall, and engine mount. The boot cowl should be done in a couple more sessions.

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Jan 21, 2020     Boot cowl - (5.5 hours)       Category: Fuselage
I got a lot done today as well; not very many pictures to show yet, but it's all coming together. More nut plates! With all the suffering, I had to bolt on a big part so I could feel like I got something accomplished. Rudder is on!

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Jan 20, 2020     Boot cowl - (2.4 hours) Category: Fuselage
No pictures to show today, but I put in a bunch of nut plates on the boot cowl. So far everything is fitting great!
 
Jan 19, 2020     Elevator trim - (1.9 hours)       Category: Fuselage
Finished fitting elevator trim tabs. Fabricated hinge pins, installed and rigged both sides. All looks great. I also fabricated hinge pins for both windows and the doors.

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Jan 10, 2020     Various - (2.8 hours) Category: Fuselage
Today I cleaned up some loose ends. I epoxied the tubing shut where I cut the elevator trim tabs, replaced a bunch of hardware on the tail with correct size stuff... oh, and nut plates! Yes, I started working on the boot cowl again. It's going well.
 
Jan 01, 2020     Trim tabs - (2.1 hours)       Category: Workshop
Well, I couldn't resist doing some work today, before my guests showed up. Cut out trim tabs and finished elevator trim torque tube. All I have left to do on the tabs/elevators is close out the cut ends with epoxy and micro balloons... then I could theoretically cover the tail!

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Dec 31, 2019     Elevator Trim - (2 hours)       Category: Empennage
Installed the elevator trim handle, turnbuckles and cables to the torque tube bell crank. There's still some work that needs to be done to the torque tube... bet we are very close to a functioning trim system. Sadly, the next couple weeks won't see much plane building; I have houseguests, then I actually get to go to recurrent training until mid January.

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Dec 30, 2019     Elevator - (3.7 hours)       Category: Empennage
We have control continuity! Installed elevator pushrod and connected both elevator halves. Everything lines up perfectly, and elevator control moves freely. Extremely happy with this result. Began installing elevator trim torque tubes, linkages, and cables.

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Dec 29, 2019     Elevators - (3.3 hours)       Category: Empennage
I cut to length and partially tensioned the tail flying wires; everything squared up nicely. Installed both elevator halves; all looks well, and elevators move freely! Also sized up and started fitting the trim torque tubes and control horns. Tomorrow, I'll run the elevator pushrod, followed by the trim actuation system.

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Dec 28, 2019     Horizontal stabilizers - (2.9 hours)       Category: Empennage
While I wait for the boot cowl rivets to show up... installed both horizontal stabilizers, lower struts, and flying wires. All fits as it should.

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Dec 27, 2019     Boot cowl - (4 hours) Category: Fuselage
Started installing nut plates for boot cowl. A bunch of drilling, and then I ran out of rivets... just my luck!! More on order!
 
Dec 26, 2019     Door frames - (2.5 hours)       Category: Fuselage
Finished aligning all door and window edge frames; riveted all in place. Also fastened fuel lines with Adell clamps.

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Dec 15, 2019     Rear windows - (3.3 hours) Category: Fuselage
More fitting of the rear window frames. Also fitted all trim work around main windows and doors.
 
Dec 14, 2019     Rear windows - (4.2 hours)       Category: Fuselage
Almost done fitting rear window frames and support stringers.

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Dec 13, 2019     Rear windows - (2.2 hours)       Category: Fuselage
Sized and fitted rear side windows and their support structure.

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Dec 10, 2019     Fuselage stringers - (2 hours)       Category: Fuselage
Finished all side and bottom stringers. Top will have to wait until I have the skylight frame installed.

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Dec 09, 2019     Stringers - (3.5 hours)       Category: Fuselage
Started installing fuselage stringers. Pretty straightforward so far, but a couple of them need to curve drastically towards the back...

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Dec 08, 2019     Throttle quadrants - (.5 hour)       Category: Controls
Fitted forward and aft throttle quadrants.

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Dec 06, 2019     Boot cowl - (2 hours)       Category: Fuselage
Enlarged all holes to 1/8��.. I need to order some hardware before proceeding.

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Dec 05, 2019     Boot cowl - (3.5 hours)       Category: Fuselage
Finished cover plate for instrument access. Fabricated gear leg intersection brackets; what the fabric will stick to behind the boot cowl, by the gear legs. Very happy with the fit of everything so far. Next, I will have to start installing god knows how many nut plates on this thing.

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Dec 04, 2019     Boot cowl - (4 hours)       Category: Fuselage
Finished fitting lower boot cowl today. It all looks pretty good, and just needs a few minor adjustments to be perfect. Measured out and cut instrument access panel. Started making a cover with .032... I will redo with .025 tomorrow. Oops.

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Dec 02, 2019     Boot cowl - (3 hours)       Category: Fuselage
Just got back from a work trip last night! Here we go again! Finished feeding lower boot cowl, and trim piece (between gear legs).

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Nov 18, 2019     Boot cowl - (2.8 hours)       Category: Fuselage
Fitted and installed lower/rear boot cowl between gear legs.

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Nov 17, 2019     Boot cowl - (3.5 hours)       Category: Fuselage
Fitted top trim piece forward of cabanes. Finished fitting sides to lower tunnel. Made template for lower pan between gear legs.

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Nov 12, 2019     Boot cowl - (2.4 hours)       Category: Fuselage
Fabricated and fitted left side boot cowl. Happy with the fit so far; next will be the bottom piece, between the gear legs.

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Nov 11, 2019     Boot cowl - (2.1 hours) Category: Fuselage
More trimming on right side. Clecoed in position; all good.
 
Nov 10, 2019     Boot cowl - (3 hours)       Category: Fuselage
Formed poster board templates for both boot cowl sides. Initial fit of right side sheet metal.... so far so good!

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Nov 09, 2019     Boot cowl - (3.8 hours)       Category: Fuselage
Fitted and clecoed top of boot cowl to instrument panel and firewall. Fabricated angle brackets to tie it all together. All looks and fits nicely. Happy so far!

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Nov 08, 2019     Fuel lines - (2 hours)       Category: Fuel System
Finished the fuel lines to the fuel selector. Everything aligns very well, with no binding on the fittings. Also trimmed the floor sheet-metal to allow space for the fuel lines and grommets.

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Nov 04, 2019     Fuel lines - (5 hours)       Category: Fuel System
Fitted all 4 fuel lines to the T fitting. All bends look good, and flares line up very well with fittings. Also drilled holes to mount the gascolator; cut aluminum floor for fuel selector standoff. Productive day!

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Nov 02, 2019     Fuel selector - (4 hours)       Category: Fuel System
Decided on final positioning of fuel selector. Fitted it to aircraft, and installed all nut plates. Also installed nut plates for instrument panel, and drilled nut plate tabs for firewall... waiting on more nut plates to show up so I can finish.

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Nov 01, 2019     Firewall fitting - (4 hours)       Category: Firewall
Finished fitting firewall and lower hot air outlet sheet-metal. Riveted together; all looks good! Nut plates next, then I really need to keep working on the fuel system... after my tubing bending fiasco, I'm really not looking forward to it.

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Oct 30, 2019     Hot air outlet tunnel fitting - (2.2 hours)       Category: Firewall
More fitting of the firewall to lower cooling air exhaust sheet-metal. It didn't seem like I got that far, but so far so good on the total fit.

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Oct 29, 2019     Fitting parts - (1.2 hours)       Category: Firewall
Fitted stainless cooling air exit ramp. Much more work needed.

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Oct 28, 2019     Firewall fitting - (1.7 hours) Category: Firewall
Started fitting firewall to lower hot air outlet.
 
Oct 27, 2019     Fitted firewall - (3 hours)       Category: Firewall
Fitted and drilled firewall. Fitted and drilled instrument panel. Everything appears to line up properly. Good day!

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Oct 25, 2019     Fuel lines - (2.0 hours) Category: Fuel System
Started bending and fitting fuel lines from the wing root to the fuel selector. Slow progress.
 
Oct 24, 2019     Rudder control - (3.5 hours)       Category: Controls
Installed toe brakes, both master cylinders. Fabricated and swaged router control cables to aft of cargo compartment. All swages within spec.

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Oct 23, 2019     Flap cable - (2.1 hours)       Category: Controls
Apparently I really needed practice with swaging. It took four tries to get the two ends of the cable swaged. Very happy with the outcome now.

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Oct 23, 2019     Pulleys - (1 hour)       Category: Controls
Installed aileron and flap control pulleys.

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Oct 22, 2019     Floors - (1.2 hours) Category: Interior Finish
Finished trimming all floor pieces; specifically around control columns.
 
Oct 22, 2019     Pulley guards - (1.1 hours)       Category: Controls
Fabricated pulley guards from .032... Took a while to get the measurements right, but eventually found an ideal forming block to make these.

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Oct 21, 2019     Stick carrier - (2.3 hours)       Category: Controls
Finished installing stick carrier, and connected to primary elevator pushrod. Nut and bolt clearance inside stick carrier was very tight and required cutting and drilling bolts to custom length. I am very happy with the outcome.

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Oct 20, 2019     Cabin floor - (2.1 hours)       Category: Interior Finish
Drilled all floor pieces for screws, and installed. Marked floors for final trimming around control columns.

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Oct 20, 2019     Installed brake calipers - (1.3 hours)       Category: Landing Gear
Installed brake calipers; plenty of space for four AN5 bolts per side. Drilled both axles for cotter pin.

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Oct 18, 2019     Floor nut plates - (5 hours)       Category: Interior Finish
Finished installing all floor nut plates.

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Oct 17, 2019     Floors - (1.3 hours)       Category: Interior Finish
Started drilling floor tabs for nut plates. Rearmost bay complete.

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Aug 31, 2019     Kit Arrived Category: Workshop
Kit arrived in Peoria safe and sound. Unpacked, inventoried all parts; great job by Avipro and Mark Goldberg for putting this kit together.
 
Aug 31, 2019     Kit Arrived Category: Workshop
Kit arrived in Peoria safe and sound. Unpacked, inventoried all parts; great job by Avipro and Mark Goldberg for putting this kit together!
 
Sep 29, 2019     Stick carrier - (2.5 hours)       Category: Controls
Fitted and installed control stick carrier and elevator idler arm. Installed more fairleads. Missing 3 from hardware kit.

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Sep 28, 2019     Flap handle - (2.3 hours)       Category: Controls
Fitted and installed flap handle assembly.

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Sep 08, 2019     Brake pedals - (0.5 hour) Category: Controls
Fitted and installed front and rear brake pedals.
 
Sep 07, 2019     Brake torque plates - (1 hour) Category: Landing Gear
Drilled all holes for brake caliper torque plates. I need hardware!
 
Sep 05, 2019     Finished floors - (2.2 hours)       Category: Fuselage
Finished fitting floor panels. Removed brake master cylinder tabs from rear rudder pedals... primed metal.

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Sep 04, 2019     Floors - (2.0 hours) Category: Fuselage
Started fitting .032 aluminum floor panels
 
Sep 02, 2019     Landing gear - (2 hours)       Category: Landing Gear
Built up main gear struts and installed gear on fuselage. Hardware store nuts/bolts will be replaced during final assembly!

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