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Project:
BearhawkPatrol
-
Listing for Category : Show all entries
(Please mouse-over any icon to get a description of that function).
Categories
Show All Entries
- (38)
Aileron
- (1)
Airbox
- (1)
Autopilot
- (1)
Avionics
- (1)
Boot Cowl
- (3)
Brakes
- (1)
Controls
Door&Window
- (1)
Elevators
- (1)
Empennage
- (1)
Engine
Eng. Baffles
- (1)
Engine Cowl
- (1)
Engine Mount
- (1)
Firewall
Flap System
- (3)
Fuel System
- (1)
Fuselage
- (2)
Inspection
- (1)
Instrument Panel
Interior Finish
- (1)
Landing Gear
- (2)
Lighting
Paint / Decals
Propeller
Research
Rotisserie
- (1)
Seating
- (1)
Tail Feathers
Throttle
- (1)
Tools
Tunnel
- (1)
Wings
- (1)
Wing Tanks
- (3)
-
Wing Tanks and Related
-
Wing Construction
-
Installing Wing Tanks
Workshop
Wing-Left
- (1)
Wing Mount
- (1)
Windshield
- (2)
Builder Name:
Bruce Case
-
Project:
Bearhawk - Patrol
-
VIEW REPORTS
Total Hours:
1383
Start/Last Date:
Jul 10, 2018 - No Finish Date
Friendly URL:
https://eaabuilderslog.org?s=BearhawkPatrol
Home or Last Project Picture
Feb 01, 2024
Engine Baffles
- (60 hours)
Category: Eng. Baffles
Modify RV Baffles to fit, create custom fiberglass inlet plenums
Pic3.jpg
Pic1.jpg
Pic2.jpg
Right Fiberglass Fairing.jpg
Left Fiberglass Fairing.jpg
Aug 06, 2023
Carb Airbox
- (8 hours)
Category: Airbox
Carb airbox from a Husky
First Airbox Fit.jpg
Jul 01, 2023
Engine Mount
- (80 hours)
Category: Engine Mount
Building new engine mount account AviPro supplied Dynafocal Mount doesn't fit on engine and is a poor design
Engine Mount-1.jpg
Engine Mount-2.jpg
Engine Mount-3.jpg
Engine Mount-4.jpg
Engine Mount Welding.jpg
Jul 01, 2023
Engine Cowl
- (60 hours)
Category: Engine Cowl
Aluminum Work associated with engine cowl
Engine Cowl-2.jpg
Engine Cowl-1.jpg
First Hinged Door.jpg
Belly1.jpeg
Belly2.jpeg
Belly3.jpeg
Cowling Jig.jpg
Dec 22, 2022
Avionics and Panel Build
- (80 hours)
Category: Avionics
Cut Out Panel,Carbon Fiber Overlay, Lots of wiring
Engraved-S.jpg
BACK OF PANEL-S.jpg
Carbon Fiber Overlay-S.jpg
Wiring-3.jpg
Nov 11, 2022
Flap System Install
- (40 hours)
Category: Flap System
Hanging flaps and rigging
Full Flaps.jpg
Flap Pulley-1.jpg
Flap Pulley-2.jpg
Flaps-1.jpg
Oct 08, 2022
Instrument Panel Fabrication
- (25 hours)
Category: Windshield
Made trail instrument panel from plexiglas to visualize any clearance issues. Remote electronics will be shelf mounted behind panel.
pic7.jpg
pic1.jpg
pic4.jpg
pic6.jpg
Sep 03, 2022
Mounting Windshield
- (42 hours)
Category: Windshield
Mounting Windshield, requires fairings at wing and at boot cowl interesection
First Fit.jpg
Fairing Required.jpg
Fairing Fit-3.jpg
Fairing Fit-1.jpg
Fairing Fit-2.jpg
Fairing-1.jpg
Fairing-2.jpg
Fairing-3.jpg
Jul 03, 2022
Mounting WIngs on Fuselage
- (100 hours)
Category: Wing Mount
Steps and jigs built to mount wings on fuselage
Backside Wing Drilling Jig.jpg
Front Wing Drilling Jig-1.jpg
Front Wing Drilling Jig-2.jpg
Water Level.jpg
Finished Product.jpeg
DSC_1841.jpg
End Mill.jpeg
Strut Drilling.jpeg
Wings Mounted.jpeg
Finished Strut.jpg
Jan 29, 2022
Various Jobs
- (100 hours)
Category: Wing-Left
Dec 18, 2021
Everything Aileron
Category: Aileron
The aileron system
Aileron Bellcrank.jpg
2nd Clearance Hole.jpg
Aileron Removable Fairlead.jpg
Aileron Strut Pulley.jpg
First Clearance Hole.jpg
Front Aileron Pully.jpg
Last Clearance Hole.jpg
Aileron Strut Pulley.jpg
Aileron Nicopress.jpg
Dec 13, 2021
Engine Stuff
Category: Empennage
Engine Related
Engine From R&B.jpg
Nov 03, 2021
Tasks Associated with Competing Wings
- (100 hours)
Category: Wings
Wing Completion
Flap Hinge Drill Jig-1.jpg
Wing Form Blocks for Alignment.jpg
Flap Hinge.jpeg
Aileron Alignment.jpg
Fairlead-1.jpg
Fairlead-2.jpg
Fairlead-3.jpg
WIre Conduit-1S.jpg
Wire Conduit-2S.jpg
Wing Interior Pex Tubing.jpg
Flap Clearance.jpg
Flap Push-Pull.jpg
Flap Springs.jpg
First Wing In Cradle.jpg
Wing Ground Strap.jpg
Wing With Hoist System.jpg
Wing Assembly Table.jpg
Aileron Rib Reinforcements.jpg
Nov 03, 2021
Wing Tanks and Related
- (54 hours)
Category: Wing Tanks
Tanks and fuel bay
Fuel Bay Right Wing-2.jpg
Fuel Bay Right Wing-1.jpg
Nov 03, 2021
Wing Construction
Category: Wing Tanks
Misc tasks associated with wing construction
Flap Hinge Drill Jig-1.jpg
Oct 07, 2021
Installing Wing Tanks
- (6.0 hours)
Category: Wing Tanks
Fuel Tank Filler Locater Jig.jpg
Fuel Filler Jig In Place.jpg
Inboard Rib From Front.jpg
Inboard Rib From Backside.jpg
Rear Tank Outlet.jpg
Fuel Tank Opening-3.jpg
Fuel Tank Opening-1.jpg
Fuel Tank Opening-2.jpg
Finished Wing on Table.jpg
Aug 24, 2021
Flap Pulley Reinforcement
- (24 hours)
Category: Flap System
Fuselage flap pulley needs reinforcement to prevent tear out of mounting bolt.
DSC_1752-S.jpg
Aug 10, 2021
Completing the elevators
- (24 hours)
Category: Elevators
I prepped the elevators today for pouring the leading edge weights. First I tacked in .025" steel plates. I brazed around the edge and smoothed them out. I was careful to keep the plates below the level of the tube edges so when the fabric is shrunk it will not contact the plates. Finally I welded in three cross dowels to give the lead an anchor.
steel plates tacked in place
brazed in place
braze smoothed out
Jun 19, 2021
Autopilot installation
- (41 hours)
Category: Autopilot
Adding three servos for autopilot
Roll Axis at Stick.jpg
Roll Axis Servo.jpg
Pitch Axis4.jpg
Pitch Axis1.jpg
Pitch Axis2.jpg
Pitch Axis3.jpg
Yaw Axis-Garmin Servo Mount.jpg
Yaw Axis Capstan.jpg
Yaw Axis Idler Pulley.jpg
Yaw Axis Overall View.jpg
Apr 01, 2021
Access Panels and Inspection
- (20 hours)
Category: Inspection
Creating inspection rings and access panels
Tail Inspection Cover Flange.jpg
Mar 23, 2021
Interior Panels and Finish
- (80 hours)
Category: Interior Finish
Finished interior with .020 aluminum painted Bearhawk gray. Applied Bearhawk logo to baggage compartment wall. Welded tabs for mounting all panels. Finished throttle cover in .090 thick aluminum, applied stencil.
Throttle Cover Plate-S.jpg
Logo.jpg
Nov 16, 2020
Custom Pilot Seat, Standard Passenger Seat
- (80 hours)
Category: Seating
Creating a new seating arrangement for the pilot to fix the bad ergonomics on the kit design. Carbon fiber bucket will get Oregon Aero cushions. Seat moves easily and also tips up to allow great access for passenger. New, narrower weldment required for pilot seat.
Carbon Fiber Seat Bucket.jpeg
Patrol Seat Frame.jpg
Pilot Seat Bottom.jpg
Seat Position Indexer-2.jpg
Seat Position Indexer-1.jpg
Off to Oregon Aero.jpg
New Seat Frame.JPG
Seat Frame Complete.pdf
Nov 14, 2020
NACA Inlet
- (6 hours)
Category: Boot Cowl
Added NACA inlets to boot cowl for human cooling. Fun CNC project.
NACA Inlet.jpg
Oct 24, 2020
Finished cutting the landing gear clearance
- (5.5 hours)
Category: Landing Gear
Using custom jugs I cut clearance holes for landing gear and CNC'd the mating gasket rings. I will use a thin rubber for the gasket. The parallel handi-lift really works well for lifting the fuselage during work on the landing gear.
pic1.jpg
pic2.jpg
Oct 16, 2020
Jig to Simulate Landing Gear Stance
- (4.2 hours)
Category: Landing Gear
In order to cut the clearance holes in the lower boot cowl for the landing gear it is necessary to simulate the landing gear in the fully compressed and extended positions. This jig allows one to simulate that without physically loading the airplane to maximum gross weight.
Shock Strut Jig.PD.pdf
IMG_1952-S.jpg
IMG_1953-S.jpg
Oct 14, 2020
Installing Pilot Doors and Right Window
- (42 hours)
Category: Door&Window
Decided to make a lockable baggage compartment and to streamline the door latch mechanism as originally designed. Using a nice cam over lock which securely pulls the baggage compartment closed. Pilots door now has a very smooth locking mechanism and nice window latches.
DSC_1676.jpg
DSC_1677.jpg
DSC_1678.jpg
DSC_1682.jpg
Sep 23, 2020
Pulley Guard for Flaps
- (6.1 hours)
Category: Flap System
Pulley guard. One piece one each side of pully. Cotter pins through holes for control cable constraint.
Pulley Guard.jpg
Sep 23, 2020
New Shop at Airport
Category: New Shop
Purchased hangar at airport for new shop
New Shop Interior.jpg
Moving Bridgeport In.jpg
Sep 23, 2020
Pilot and Baggage Door
- (28 hours)
Category: Fuselage
Aluminum for pilot and baggage door fitted. Need to add locking mechanisms
Baggage Door.jpg
Aug 01, 2020
Airplane Rotator
- (24.2 hours)
Category: Rotisserie
Build a rotisserie which allows for easy access to the airplane while building and covering. Harbor freight engine stands were modified along with a custom indexing system using a agriculture PTO drive and a 40 tooth gear with a spring loaded pin for positive indexing.
2AFE3CE1-5070-448C-955E-7A40439F4789.jpeg
Overall Shot.jpg
Mechanism #2.jpg
Rotating Mechanism.jpg
May 03, 2020
Left Rear D Window Install
- (18 hours)
Category: Fuselage
Made the mounting of the D window so it would flush out with the pilot window ahead of it. Final plexiglass and fabric to do before final riveting.
IMG_1299.jpg
IMG_1300.jpg
IMG_1302.jpg
Drill Jig Assembly.jpg
IMG_1312.jpg
DSC_1610-S.jpg
DSC_1613-S.jpg
DSC_1616-S.jpg
DSC_1617.jpg
DSC_1620-S.jpg
Mar 07, 2020
Wedge filler on boot cowl wrap around
- (3.0 hours)
Category: Boot Cowl
Small tapered wedge requires on bottom of boot cowl wrap around to tunnel. Only one side required this.
39DCE258-7740-43CE-B4B2-13AA84E59B5F.jpeg
8A1E5B7B-C3D9-4482-8FAF-7A197F6272F5.jpeg
Dec 14, 2019
Boot Cowl Installation
- (38 hours)
Category: Boot Cowl
Installing Top Boot Cowl and Cutout Panel
DSC_1574.jpg
DSC_1575.jpg
DSC_1576.jpg
DSC_1577.jpg
DSC_1578.jpg
DSC_1579.jpg
Lots of Nut Plates
DSC_1581-S.jpg
DSC_1582-S.jpg
DSC_1583-S.jpg
Nov 03, 2019
Tunnel and Bottom Boot Cowl
- (11 hours)
Category: Tunnel
Bottom tunnel mounting and mating to bottom boot cowl aluminum
DSC_1521.jpg
DSC_1522.jpg
DSC_1523.jpg
DSC_1568.jpg
DSC_1569.jpg
DSC_1570.jpg
DSC_1571.jpg
DSC_1573.jpg
Oct 10, 2019
Installing Fuel System
- (85 hours)
Category: Fuel System
Bearhawk Patrol has front and back fuel feeds from each overhead tank. Used 5000 series aluminum tubing with minimum joints. Gold cube fuel flow transducer installed just before firewall.
DSC_1527.jpg
DSC_1528.jpg
DSC_1529.jpg
DSC_1530.jpg
DSC_1530.jpg
DSC_1538.jpg
DSC_1547.jpg
Fuel Line Retainer-2.jpg
Fuel Line Retainer-1.jpg
Fuel Plumbing-2S.jpg
Fuel Plumbing-1S.jpg
Sight Glass Rear.jpg
Fuel Line.jpg
Sight Glass Front.jpg
Oct 10, 2019
Installing brake system
- (45 hours)
Category: Brakes
Brake system design and install. Uses a parking brake.
DSC_1525.jpg
DSC_1526.jpg
DSC_1528.jpg
DSC_1529.jpg
DSC_1530.jpg
DSC_1531.jpg
DSC_1533.jpg
DSC_1535.jpg
DSC_1533.jpg
DSC_1535.jpg
DSC_1537.jpg
DSC_1541.jpg
DSC_1542.jpg
Oct 10, 2019
Designing and Installing Custom Throttle Quadrant
- (43 hours)
Category: Throttle
Designed and built a custom throttle quadrant to solve problem of interference with flap handle.
DSC_1557-S.jpg
DSC_1559-S.jpg
DSC_1561-S.jpg
DSC_1565-S.jpg
SHORTER THROTTLE ASSEMBLY.PD.pdf
Throttle Cover Plate-S.jpg
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