Project: PA-22SuperPacer   -  
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Builder Name:Alan Levinson   -  
Project:   Piper PA-22 Super   -   VIEW REPORTS
Total Hours:1121.8
Total Flight Time:2
Start/Last Date:Nov 09, 2018 - No Finish Date
Engine:Lycoming O-320-B1A
Propeller:McCauley 1A175/GM8244
 
Friendly URL: https://eaabuilderslog.org?s=PA-22SuperPacer

Home or Last Project Picture

Jun 01, 2023     Rudder bar and cables - (4 hours)       Category: Fuselage
Temporarily install rudder bar, master cylinders, rudder cable w/ pulleys. Measure length needed, add 21.75". Old cable 180.125". Clean up parts, cut fittings off old cables, and prime paint.

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May 31, 2023     Move parts storage - (2 hours) Category: Workshop
Move parts stored in greenhouse to garage and shed.
 
May 30, 2023     Rudder bar and stab yoke - (8 hours) Category: Fuselage
Found rudder bar clamps, installed rudder bar temporarily. Installed horizontal stab trim yoke.
 
May 26, 2023     Controls - (2 hours) Category: Fuselage
Clean up from painting. Put things away. Start assembling control column. Put vertical stab on fuselage.
 
May 21, 2023     Painting parts - (3.5 hours)       Category: Fuselage
Prep and prime Ekopoxy rudder bar, rudder pedals, stab trim yoke, vertical stab, engine mount.

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May 19, 2023     Rudder bar - (2.5 hours) Category: Fuselage
Disassembled and cleaned rudder bar.
 
Apr 30, 2023     Mostly finish temp temp landing gear       Category: Landing Gear
Finish bracing. Just need two casters.

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Apr 29, 2023     Painting - (4 hours) Category: Fuselage
Paint Stewart's top coat on fuselage where small welding was done and control column, flap handle and elevator bellcrank.
 
Apr 29, 2023     Make shop gear - (3 hours)       Category: Landing Gear
Start building temp main gear out of unistrut. It will be narrower than real gear and a little shorter. Easier to work around until wings go on.

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Apr 28, 2023     Painting - (4 hours) Category: Fuselage
Paint Stewart's primer on fuselage where small welding was done and control column, flap handle and elevator bellcrank.
 
Apr 16, 2023     Finish RH wing - (4.5 hours) Category: Wings
Finish up details, rig flap. Move OB aileron fairlead aft for top cable to clear rib. Moved wing back onto cart.
 
Apr 15, 2023     RH wing - (2.5 hours) Category: Wings
Put in correct larger drag wire. Finish screws in tank bay LE.
 
Apr 14, 2023     RH wing - (1 hour) Category: Wings
Set reference points for trammeling bay where drag wire has to be changed out.
 
Apr 14, 2023     Find bearings - (2 hours) Category: Research
Call several places to order bearings for lower control column to airframe.
 
Apr 13, 2023     Took airframe to welder - (1 hour) Category: Fuselage
Took airframe to Sam Porter to finish welding up tubes that box in tail.
 
Apr 09, 2023     Baggage door frame - (5 hours) Category: Fuselage
Put rivnuts in top of door frame for interior panels. Sorted through flap pulleys, found a couple of damaged ones. Went through aileron pulleys, a couple of bearings are rough. Ordering some replacements.
 
Apr 08, 2023     Baggage door frame - (1 hour) Category: Fuselage
Found pieces for door frame and started to assemble. Need to consult tear down pictures.
 
Apr 08, 2023     Welding - (2 hours) Category: Fuselage
Tried setting up oxy-acetylene torch and practicing on scrap. No luck, kept popping and blowing holes in tubing.
 
Apr 08, 2023     Cleanup and parts - (2 hours) Category: Workshop
Clean up some things. Get parts from shed for fuselage.
 
Apr 02, 2023     RH wing - (3.5 hours) Category: Wings
Make one aileron cable. Install aileron cables. Put in fairleads. Put in last few false spar stiffener channels. Put inspection hole on OB flap bellcrank. One long stiffener on rear of butt rib.
 
Apr 01, 2023     Looking for ELT - (1.5 hours) Category: Research
Looking for info on ELT purchase and install.
 
Apr 01, 2023     Clean up - (2 hours) Category: Workshop
Clean up from painting. Clean and assemble spray gun. Put things away. Sweep the floor.
 
Mar 31, 2023     Airframe top coat - (3 hours) Category: Fuselage
Turned airframe LH side down. Spraying top coat. Ran out of 2nd qt of Insignia White Aerothane.
 
Mar 30, 2023     Airframe top coat - (5 hours) Category: Fuselage
Fuselage on RH side. Spraying top coat.
 
Mar 28, 2023     Airframe top coat - (4 hours) Category: Fuselage
Airframe right side up. Spraying top coat. Tiki and Thea got another qt of Aerothane paint in Fairbanks.
 
Mar 26, 2023     Prime paint - (1.5 hours) Category: Fuselage
Spray primer on backseat lower tube. Clean up a little. Out of Aerothane top coat epoxy.
 
Mar 24, 2023     Painting airframe - (10 hours) Category: Fuselage
Airframe upside down. Started spraying top coat Aerothane insignia white.
 
Mar 23, 2023     Prime paint airframe - (2.5 hours)       Category: Fuselage
Turn airframe upside down. Final spraying of dark green primer. Ended up using 1 qt white primer, and 0.8 qt dark green primer.

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Mar 22, 2023     Primer painting airframe - (2.5 hours)       Category: Fuselage
Turned fuselage right side up. Painted on more dark green.

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Mar 21, 2023     Prime airframe - (4.5 hours) Category: Fuselage
Turned airframe onto LH side. Continue primer painting w/ dark green.
 
Mar 20, 2023     Painting primer on airframe - (6.5 hours)       Category: Fuselage
Turned airframe on to RH side w/ front on a half height saw horse. Started painting w/ dark green primer.

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Mar 18, 2023     Spraying primer - (4.5 hours) Category: Fuselage
Spraying primer on fuselage tubing.
 
Mar 17, 2023     Prime paint - (8 hours)       Category: Fuselage
Started brushing on white primer then switched to spraying. Very slow going.

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Mar 16, 2023     P/u fuselage - (5 hours)       Category: Fuselage
Got fuselage from sandblasting in Fairbanks. Also p/u more 100' control cable Nicopress sleeves, and thimbles.

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Mar 12, 2023     Finish little bits - (4.5 hours) Category: Wings
Put fairleads in LH wing. Check routing of aileron cables. Put inspection frame on RH wing IB flap bellcrank. Put in stiffeners between ribs to false spar.
 
Mar 11, 2023     Aileron cables - (4 hours) Category: Wings
Remake aileron cables with correct thimbles. Started to install in wings with fairleads.
 
Mar 10, 2023     Sandblasting - (5 hours)       Category: Fuselage
Took fuselage to Fairbanks to get sandblasting. Picked up Polyfiber epoxy primer (2 qts, 2 colors) and Aerothane top coat.

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Mar 04, 2023     Change angle of strut fittings - (6 hours)       Category: Fuselage
Installed wings on fuselage with JW and Greg's help. Leveled fuselage and adjusted wing dihedral to PA-22 specs (4 ⅞"). Heated strut fittings with rose bud torch and lowered fitting angle with 16" Crescent wrench. Measured length for front strut=121 23/32", rear 125 9/32.

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Mar 04, 2023     Temp gear - (1.5 hours)       Category: Landing Gear
Got a 3' stick of tubing that slides into the shock strut tube. Installed on fuselage w/ axles level. Then marked and drilled tubing. Now have solid landing gear.

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Feb 26, 2023     Move wings to JW's hangar - (3 hours)       Category: Wings
Move wings to JW's hangar to mount on fuselage. Precursor to bending the fuselage strut fittings to a shallower angle to adjust for the longer wing and strut fitting on wing being farther OB.

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Feb 26, 2023     RH wing - (3 hours)       Category: Wings
Attach false spar to ribs in cove area. Rivet IB flap hinge bracket to false spar. Temporarily install aileron and flap. Adjust flap push rods to match aileron trailing edge. Attach everything to flap bellcrank.

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Feb 25, 2023     Wing stands - (7 hours) Category: Workshop
Construct stands to support the wings on the fuselage w/o struts.
 
Feb 23, 2023     Fit temporary landing gear - (3 hours) Category: Fuselage
Got old beat up landing gear from Sutton Aircraft Salvage for $10! Had to grind a little off the RH gear to fit the fuselage fittings. Mounted gear and wheels (from Truman) and tied rope between legs to hold together. Put old 6" Scott t/w on Citabria tail spring and mounted on fuselage. Fuselage is somewhat mobile now!
 
Feb 23, 2023     Aileron cables - (2.5 hours) Category: Wings
Figure out length for new cables. Thought about purchasing new link plates for the IB ends but decided to cut the old cables and retrieve the plates. Sandblasting the plates and going to paint. Remove all of the fairleads so that I can make the new cables on the bench and install.
 
Feb 21, 2023     Finishing up - (2 hours) Category: Wings
Put rub strip on IB flap hinge bracket for aileron cables going by. Research aileron cable assembly.
 
Feb 20, 2023     Finishing up - (5 hours) Category: Wings
Replace center flap hinge bearing block to get better hinge alignment. Install pitot tube plumbing.
 
Feb 18, 2023     Bracing - (3 hours) Category: Wings
OB tank bay rib bracing installed. False spar bracing installed.
 
Feb 17, 2023     Bracing - (1.5 hours)       Category: Wings
Put bracing on tip rib. Put bracing on butt rib.

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Feb 12, 2023     Rib bracing - (1 hour) Category: Wings
Started to make some bracing for the tip rib.
 
Feb 11, 2023     False spar and flap bellcrank - (6 hours) Category: Wings
Lift up tank bay false spar to remove temporary bolts from IB flap bellcrank that were inserted from the top. I install all new bolts from the bottom up, cotter pinned,on both flap bellcranks. Drilled false spar for bracing to rear spar.
 
Feb 10, 2023     False spar - (1 hour) Category: Wings
Drilling some holes for rib trailing edge attachment.
 
Feb 05, 2023     Aileron and flap hangers - (1.5 hours) Category: Wings
Rivet hinge brackets to false spar.
 
Jan 19, 2023     False spar - (1.5 hours) Category: Wings
Double false spar @ OB aileron hinge bracket. Drill bracket support holes in false spar.
 
Jan 18, 2023     False spar - (1.5 hours) Category: Wings
Drilling false spar for aileron and flap hinge brackets.
 
Jan 04, 2023     False spar - (2 hours) Category: Wings
Hang aileron and flap. Determine clearances on ends and flush with bottom of wing.
 
Jan 03, 2023     Tank bay - (2 hours) Category: Wings
Reinstall LE and partially trailing edge.
 
Jan 01, 2023     Tank bay - (2 hours) Category: Wings
Install nutplates @ LE and trailing edge.
 
Dec 24, 2022     Tank bay - (2 hours) Category: Wings
Dimpling LE, false spar for nutplates. Riveted 2 nutplates on.
 
Dec 17, 2022     Tank bay cover - (3 hours) Category: Wings
Layout tank cover holes in LE and trailing edge skins. Removed skins and drilled screw holes and rivet holes for floating nutplates.
 
Dec 04, 2022     Tank bay - (4.5 hours)       Category: Wings
Riveted doubler onto false spar. Layed out tank bay false spar extension for larger bay. Cut and fit, drilled, and attached. Attached inspection holes on underside. Attached false spar. Layed tank in bay, put cover on, found bay too wide front to back @ OB side. Removed false spar extension, layed in line with false spar using a straight edge instead of the rear spar. It moved the extension fwd about 5/16". Removed LE screws in front spar, put straps on to try and sqeeze it in tighter to ribs and move tank lid attachment strip rearward.

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Dec 03, 2022     False spar - (1 hour)       Category: Wings
Flap bracket doubler, layout and drill rivet pattern.

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Dec 02, 2022     False spar - (3 hours) Category: Wings
Tank bay false spar drilling holes for ribs. Notch inspection hole plate to fit around ribs and tank strap @ rear spar. Also drilled for rib attachment.
 
Nov 29, 2022     Tank bay false spar - (2 hours) Category: Wings
Drilled rear spar for OB flap bellcrank return spring attachment. Drilled tank bay false spar and rear spar for attachment. Layed out locations for screws into ribs along top surface.
 
Nov 28, 2022     Tank bay false spar - (.5 hour) Category: Wings
Fitting flap actuator rod opening.
 
Nov 27, 2022     False spar - (2.5 hours) Category: Wings
Riveted in doubler for OB flap bellcrank. Started cutting hole for IB flap actuator rod.
 
Nov 25, 2022     False spars - (4.5 hours) Category: Wings
Fitting 3rd IB spar. Cut slot for OB flap rod. Work on fitting flap bracket doubler next.
 
Nov 22, 2022     False spar - (2 hours) Category: Wings
Installed inspection hole @ OB flap bellcrank.
 
Nov 21, 2022     Cable fairleads - (3.5 hours)       Category: Wings
Put flanges on rib plate for fairlead support. Riveted in rib plate. Start fitting OB false spar to permanently install.

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Nov 20, 2022     Cable fairleads - (5 hours) Category: Wings
Make 3 rib plates to support the cable fairleads. Rivet one in place @ center flap hinge to guide flap interconnect cable.
 
Nov 19, 2022     Cable fairlead - (3 hours)       Category: Wings
Making aluminum cable fairlead supports to go in a rib plate.

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Nov 18, 2022     Flap and aileron hangers - (4 hours) Category: Wings
Drilled aileron hinge brackets for false spar attachments. Trying to figure out aileron and flap cable fairleads.
 
Nov 17, 2022     False spar - (1 hour)       Category: Wings
Cutting and fitting 2nd and 3rd false spar.

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Nov 17, 2022     False spar - (1 hour) Category: Wings
Cut last, 3rd, false spar for length. Put rivet plates on aileron hinge brackets to mark location to be drilled and screwed.
 
Nov 14, 2022     False spar - (1 hour) Category: Wings
Cut and fit tank bay false spar on flap hinge bracket, butt rib, and tank straps.
 
Nov 13, 2022     Flap cable and false spar - (3 hours) Category: Wings
Made flap cable that connects IB and OB flap bellcranks. Started @ OB false spar cutting around aileron hinge brackets and cutting for length. Starting to cut 2nd IB false spar.
 
Nov 12, 2022     Nicopress - (2 hours) Category: Wings
Went over to JW's to borrow Nicopress crimper. Started getting together pieces for flap cable.
 
Nov 10, 2022     Trailing edge - (4 hours) Category: Wings
Gathering pieces and parts for the flap bellcranks, etc.
 
Nov 08, 2022     Trailing edge - (2 hours) Category: Wings
Reinstall flap and aileron hinge brackets after painting small parts.
 
Nov 07, 2022     Painting - (1.5 hours) Category: Wings
Finish painting small pieces. Clean up paint sprayer.
 
Nov 06, 2022     Flaps and ailerons - (4.5 hours) Category: Wings
Painted small steel parts. Installed bracket for pitot tube on rear spar.
 
Nov 05, 2022     Install parts on rear spar - (6 hours) Category: Wings
Drilled holes in spar for flap bellcrank brackets and pitot bracket.
 
Nov 04, 2022     Parts for trailing edge - (3 hours) Category: Wings
Sandblasted an aileron hinge bracket, flap bellcrank brackets, fairlead brackets, drag wire clevis's. Used JW's blast cabinet. Parts were off ebay except for aileron bracket. Then drilled an angle backer for center flap hinge bracket.
 
Nov 02, 2022     Fitting aileron and flap - (2 hours) Category: Wings
Clean rust out of aileron hinge bracket. Drilled new bearing block. Installed center aileron hinge bracket. Checking aileron hinge pins alignment and adjusting brackets.
 
Nov 01, 2022     Fitting aileron and flap - (3 hours)       Category: Wings
Removed IB aileron bracket bearing block. Put in new bearing block and aligned aileron and flap trailing edge adjusting bearing block location, clamping and marking.

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Oct 30, 2022     LE install, moving on to trailing edge - (5 hours)       Category: Wings
Drilled ribs on top side of LE and installed screws. Cut opening for landing light. Starting to figure out aileron and flap brackets.

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Oct 29, 2022     LE skins - (3 hours)       Category: Wings
Finished attaching LE skins to spar on top.

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Oct 28, 2022     LE skin - (7 hours)       Category: Wings
Finished attaching bottom of skins to ribs. Then Dean stopped by and helped me turn wing over. Leveled wing and put stands under wing hinge and strut fittings to put washout in. Verified washout with digital level. Got OB skin attached to spar. Starting to attach 2nd OB skin.

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Oct 27, 2022     LE skins - (4 hours) Category: Wings
Finished attaching all of LE skins to bottom of spar.
 
Oct 26, 2022     LE install - (2.5 hours) Category: Wings
Finished deburring notches in LE skin. Started installing bottom side of OB skins.
 
Oct 23, 2022     LE skin - (3.5 hours) Category: Wings
#2 OB skin got flipped upside down and marked and notched for ribs, Atlee Dodge tie down, and strut fitting. SO, had to reverse the bend radius on the skin to accommodate the wrong orientation. It took some time and figuring but I think it may have worked out successfully. We will see when it is attached to the ribs if it lays correctly.
 
Oct 22, 2022     Notching LE skins - (4 hours)       Category: Wings
Finish cutting notches for ribs and tank straps. Then filing a daily deburred most of the skins. Put varnish on all of the fabric chafe tape at drag wire intersections and rib bracing close to drag wires.

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Oct 21, 2022     LE skins - (5 hours)       Category: Wings
Notch LE skins for ribs. Put fabric chafe tape on ribs where wires are tied.

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Oct 19, 2022     LE skin - (1 hour) Category: Wings
Cutting notches in 1st skin. Marked 2nd skin for length.
 
Oct 17, 2022     LE skins - (1 hour) Category: Wings
Started notching 1st skin for ribs.
 
Oct 16, 2022     Starting on leading edge - (4 hours) Category: Wings
Clean up shop. Earl helped me flip wing over. Cut 1st LE skin for length and then began marking where notches need to be cut for ribs.
 
Oct 15, 2022     Wiring, rib lacing - (5 hours) Category: Wings
Added OAT sensor wiring into bundle. Tied wires to all of the ribs ahead of the main spar. Put rib lacing in and tensioned to hold front of ribs square.
 


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