Project: rtardiff   -  
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Builder Name:Richard Tardiff   -  
Project:   Bearhawk - Patrol   -   VIEW REPORTS
Total Hours:2319.25
Total Flight Time:0.7
Total Expense:$39.00
Start/Last Date:Aug 10, 2019 - No Finish Date
Engine:Lycoming 0360
 
Friendly URL: https://eaabuilderslog.org?s=rtardiff

Home or Last Project Picture

Mar 13, 2024     Regrouping - (2 hours) Category: Research
Spent a few hours reviewing the work I'd left behind, searching for and ordering a prop. governor, some paint, and lexan for the skylight.
 
Feb 11, 2024     Island Time       Category: R&R
Taking a few months at home. (Kona) for R '& R. (repairs & renovations--old house, old car, older man!)


 
Nov 06, 2023     More details - (3 hours) Category: Cowling
On Saturday, I epoxied two layers of carbon fiber cloth on the inside of the nose bowl--I had gotten a bit carried away with my efforts to countersink the attachment screws. Given the tendency of the cf to crumble, I've decided to install oval-head screws.
 
Nov 04, 2023     WING TIPS - (2 hours)       Category: Wings
Drilled flanges to accept nut plates.


 
Nov 03, 2023     Wing Tips - (12 hours)       Category: Wings
Carbon fiber wing tips from Bob Barrows--very good fit out of the box. However, in order to install flush with the wing skins, a few extra steps are needed. First, the rivets must be drilled out of the outer rib. Next, an aluminum strip is inserted between the rib and skin to form a backer for the wingtip. Strips are match drilled & dimpled to receive rivets. A bit of trimming/sanding allows a tight fit to the wing. More match drilling: this time, through the carbon fiber and backer. Nutplates in the backing strip will allow for easy removal of wingtips at inspection time. Cargo straps provide an extra hand while snugging the wingtip up at the leading edge.


 
Oct 24, 2023     Nose Bowl. Finished?       Category: Cowling
Not quite finished, but getting closer. A bit more sanding needed.


 
Oct 19, 2023     Nose Bowl, continued - (8 hours)       Category: Cowling
More sanding and filling. Trying to get a smooth transition between the nose bowl and cowling.


 
Oct 13, 2023     Air Box - (14 hours)       Category: Cowling
Carb. Box received from Avipro. Starting with a 2" hole approximately centered on carburetor, gradually cut opening to accommodate the air box/filter assembly. Fabricated the air scoop from .025 sheet. lk


 
Oct 06, 2023     Fill, Sand, repeat as needed - (10 hours)       Category: Cowling
It takes a bit of time and patience for a flush fit, but should be worthwhile. Used a thick slurry of epoxy/microbeads to build up a flange in front of cowling pieces.


 
Sep 29, 2023     Cleaning Day - (6 hours) Category: Workshop
Re-organized, swept, etc.
 
Sep 28, 2023     Cowl doors - (6 hours)       Category: Cowling
Fit cowl doors; attached piano hinges.


 
Sep 27, 2023     Cowling, continued - (10 hours) Category: Cowling
Riveted lower cowl to aluminum angles; re-hung propelle & spinner.
 
Sep 25, 2023     Exhausting! Still. - (4 hours)       Category: Engine
Pulled and re-installed Vetterman exhaust, using hangers, gaskets, provided. checked fit with lower cowl. Couldn't ask for a better match.


 
Sep 19, 2023     This may take some time... - (21 hours) Category: Cowling
Continued gradual adjustment of cowling fit. Replaced lower channels with 3/4 angles. Ordered carb. box from Avipro. (4 days). Top and bottom sections appear to be locked in.
 
Sep 16, 2023     Prop. off! - (.75 hour) Category: Propeller
Pulled the propeller assembly in order to remove the plywood spacer needed to establish the gap between spinner and nose bowl
 
Sep 15, 2023     Bottoms Up - (4 hours)       Category: Cowling
Fit the bottom cowl section to the nose bowl.


 
Sep 14, 2023     Two steps back - (5 hours)       Category: Cowling
Not sure what I missed in the instructions, but I found that, having cut the top cowling section down to the 13" width, I was left with a gap between the top and bottom sections that was to great for the door panels supplied in the kit. Accordingly, I sourced a larger piece of .032 aluminum and made a large (21 " wide) panel. Replaced the piano hinges, etc.


 
Sep 13, 2023     Three steps forward... - (7 hours) Category: Cowling
Adjusted, re-adjusted, then adjusted the lower cowling some more.
 
Sep 12, 2023     Fitting bottom Cowl Section - (06 hours)       Category: Cowling
Found & replaced mis-matched nut plates at the boot-cowl/firewall joint. Began fitting lower cowl section.


 
Sep 09, 2023     Channels       Category: Cowling
Preliminary fit of lower channels that support the lower cowl and house the Dzus fasteners. Trick is to center the nose bowl behind the spinner. This may take a couple of tries!


 
Sep 08, 2023     HINGES - (3 hours)       Category: Cowling
Fit piano hinges to top cowl section


 
Sep 08, 2023     ELEVATOR RE-BALANCE - (2 hours)       Category: Empennage
CLEANED UP AND SANDED ELEVATORS IN PREPARATION FOR PATCH & PAINT


 
Sep 06, 2023     Thrilling Drilling - (06 hours)       Category: Tail Feathers
After months of avoidance, I took a day to drill out the excess lead in the elevators. They are now balanced, per the designer, at the hinge point.


 
Sep 05, 2023     Cleanup DAY - (4 hours) Category: Workshop
Put away tools, updated build log, etc.
 
Sep 02, 2023     Exhaust - (2 hours)       Category: Engine
The exhaust arrived from Vetterman. Pleased to find that it assembles easily, and appears to fit the engine. Critically, it will also fit under the cowl as designed--no cutouts or other modifications needed. I did note that one of the exhaust studs has gone missing. Another order from ASC...


 
Sep 01, 2023     Cowling.2 - (4 hours)       Category: Cowling
Continued measuring & positioning the nose bowl. Cut and fit the top section of the cowling.


 
Aug 31, 2023     Cowling.1 - (4 hours) Category: Cowling
Began the process of aligning the nose bowl with the firewall, etc.
 
Aug 29, 2023     Parts - (3 hours) Category: Research
Researched and ordered battery, hinges (for cowling), and misc. hardware
 
Aug 28, 2023     Spinner/Propeller - (5 hours)       Category: Propeller
Installed nut plates on spinner bulkhead. Reinstalled propeller. Plywood spacer aft of spinner bulkhead establishes spacing between nose bowl and spinner. The cowling will flow aft to the firewall.


 
Aug 26, 2023     GEOMETRY - (4 hours)       Category: Propeller
The forward spinner bulkhead, when mounted has no access from the outside. Accordingly, locating the screw holes on the spinner is a head-scratcher. Plane geometry to the rescue! Using a shop-built compass, and with the spinner removed from the prop. hub, I triangulated the locations, based on the previously-drilled mounting holes at the rear bulkhead. Sixty years later, I'm so glad I paid attention in Mr. Bryant's class!


 
Aug 23, 2023     Spinner - (10 hours)       Category: Propeller
Fit spinner to rear bulkhead. This involved mounting and removing the propeller several times, in order to get the correct relationships among crankshaft flange, firewall, nose bowl, and spinner. A 3/8" plywood ring between the nose bowl and spinner establishes the spacing.


 
Aug 22, 2023     Metal Prep - (6 hours) Category: Propeller
Scuffed, acid etched and alodined the spinner bulkheads; assembled the rear bulkhead (two pieces)
 
Aug 12, 2023     Oil Cooler Shroud - (6 hours)       Category: Engine
According to the several sources, and based on my inspection of the previous installation of my engine, the practice of hanging the oil cooler from the rear baffles can result in cracks. Decided to hang the oil cooler on the firewall. Fabricated a shroud to direct cooling air to the oil cooler.


 
Aug 09, 2023     Back to the Books - (5 hours) Category: Research
Reviewed the Bingelis and Prizio books to get a better picture of what needs to be done with the engine
 
Jul 17, 2023     Company Coming - (3 hours)       Category: Workshop
Cleaned up the hangar in preparation for a visit from EAA Chapter 517. A dozen guests came by to take a look at the project.


 
Jul 13, 2023     Spinner. 2.0 - (4 hours)       Category: Propeller
Per Van's instructions, I began to fit the spinner bulkhead to the propeller hub. Lots of tracing, trimming, and filing.


 
Jul 11, 2023     Details - (5 hours)       Category: Interior Finish
Installed the pilot seat belt, added a knob to the trim control, and riveted the Plexiglas on the pilot door.


 
Jul 10, 2023     Orders of the day - (2.5 hours) Category: Workshop
After much head-scratching and further reading, I ordered the spinner and hardware kit from Van's. To their credit, they shipped the items within an hour!
 
Jul 08, 2023     Trim Controls - (2 hours)       Category: Controls
Re-assembled trim control on left side-wall. Will need adjustment when the tail feathers are reattached.


 
Jul 06, 2023     Doors - (4 hours) Category: Fuselage
Assemble and hang cargo & pilot doors
 
Jul 04, 2023     Why Doesn't the Spinner Fit? - (2 hours) Category: Research
I had hoped to reuse the spinner from the C175 that donated the engine/prop. Upon hanging the propeller, it became all too clear that the old spinner and the carbon fiber nose bowl sourced from Bob Barrows were not compatible. Van's seems to have a solution.
 
Jul 03, 2023     CLEANUP DAY - (4 hours) Category: Workshop
 
Jul 01, 2023     MOUNT PROPELLER - (1.5 hours)       Category: Propeller


 
Jun 29, 2023     Mount Up, Part 2 - (5 hours)       Category: Engine
With the help of my trusty assistant, managed to get all four bolts secured. Engine is hung!


 
Jun 28, 2023     Mount UP. Part 1 - (3 hours)       Category: Engine
Worked at fitting engine mount to engine and vice versa.


 
Jun 27, 2023     Panels, again - (6 hours) Category: Interior Finish
Continued fitting interior panels.
 
Jun 26, 2023     We're covered - (6 hours)       Category: Interior Finish
Installed seats over kit frames. Sourced from Sport Aircraft Seats.


 
Jun 23, 2023     Have a Seat! - (4 hours)       Category: Interior Finish
Prepped seat frames for cover.


 
Jun 21, 2023     Pedals - (2.5 hours) Category: Controls
Cut and fit tubing for hinge; Reinstalled rudder pedals.
 
Jun 21, 2023     Just call me Sparky - (2.5 hours) Category: Research
Dug into the subject of ignition harnesses. No conclusion at this time. Ordered misc. parts.
 
Jun 20, 2023     Seat Tracks - (4 hours) Category: Fuselage
After much dithering and cogitation, worked up the courage to drill the seat tracks. Anticlimax defined.
 
Jun 16, 2023     Details - (1.5 hours) Category: Interior Finish
Reattached interior panels.
 
Jun 14, 2023     Reassembly - (2 hours) Category: Controls
Reassembled throttle quadrant
 
Jun 14, 2023     Rear bulkhead - (1 hour) Category: Paint / Decals
Shot rear bulkhead panel with white Airtech
 
Jun 12, 2023     Floor Boards - (3 hours) Category: Paint Prep.
Cleaned and scuffed floor panels in preparation for application of spray-on bed-liner. Reasoned that if it's tough enough for a pickup bed....
 
Jun 12, 2023     Seat Belts Save Lives - (2 hours)       Category: Research
More research and deliberation on seatbelts/harnesses. Finally settled on harness/belt combination from WagAero.


 
Jun 09, 2023     Trim - (2 hours) Category: Interior Finish
Fit interior trim pieces/
 
Jun 08, 2023     More paint - (2 hours) Category: Paint / Decals
Prepped rudder pedals for paint
 
Jun 07, 2023     Cargo Door - (4 hours) Category: Fuselage
Drilled, demurred, etc. Attached skin to cargo door using pulled rivets.
 
Jun 06, 2023     It's the little things - (3 hours) Category: Paint / Decals
Took a bundle of small parts--trim pieces, etc., into the booth and repainted with Airtech.
 
Jun 05, 2023     EXHAUSTING! - (4 hours)       Category: Research
Consulted EAA, several friends, and finally, the folks at Vetterman. Exhaust system order has been placed!


 
Jun 01, 2023     Hang On! - (1 hour)       Category: Propeller
Bolted propeller to engine for the first time.


 
Jun 01, 2023     Spruce Day - (3 hours)       Category: Workshop
Having finally installed wifi in the hangar, I was able to place a hardware order without leaving the airport! Life is good.


 
Jun 01, 2023     Interior tubing - (3 hours)       Category: Paint / Decals
Finished masking interior. Sprayed exposed tubing with flat black.


 
May 31, 2023     Interior Prep - (6 hours) Category: Paint Prep.
A wise person once told me, "Thou shalt not stray from the critical path!" She was right. I should have painted the interior tubing before I covered the fuselage. I didn't, and that meant carefully masking the fabric and other white places inside the cockpit and baggage area.
 
May 30, 2023     Interior tubing - (1.5 hours) Category: Paint Prep.
Began masking prior to painting exposed interior tubing with flat black.
 
May 29, 2023     Fiberglass 2 - (2 hours)       Category: Paint Prep.
More sanding & filling--fairings @ stop & bottom of wing strut (new apprentice is working out great)


 
May 25, 2023     Fiberglass 1 - (1.5 hours) Category: Paint / Decals
Sanded & filled several fiberglass fairings
 
May 24, 2023     RE-prep - (3 hours) Category: Paint / Decals
Cleaned & sanded several small parts for re-paint
 
May 23, 2023     Flat Black - (6 hours)       Category: Paint / Decals
Sprayed door & window frames, engine mount, etc. with flat black.


 
May 22, 2023     Accent Colors - (5 hours) Category: Paint / Decals
Prepped door & window frames, engine mount, etc. for paint.
 
May 19, 2023     Engine-Prop-Spinner - (2 hours) Category: Research
Consulted several books & websites regarding the prop-spinner combination.
 
May 19, 2023     Small Parts Need Paint, Too - (3.5 hours) Category: Paint / Decals
Primed and painted trim pieces
 
May 18, 2023     Lots of little pieces - (6 hours) Category: Paint Prep.
Prepped more small pieces for paint. Rounded up missing parts from storage.
 
May 17, 2023     A Clean Engine is a Happy Engine - (2 hours)       Category: Engine
Removed cracked baffles and old baffle seals. Began cleaning engine. Started orientation with new apprentice.


 
May 15, 2023     Prime Struts - (2 hours) Category: Paint / Decals
Shot both wing struts with AirTech epoxy primer
 
May 13, 2023     More of the same - (6 hours) Category: Paint Prep.
Continued with paint prep--small parts.
 
May 13, 2023     Wing 2 - (7 hours) Category: Paint / Decals
Cleaned, acid etched, alodined 2nd wing.
 
May 11, 2023     Struts Get Prepped - (2.5 hours) Category: Paint Prep.
Pulled attach brackets off wing struts; cleaned with Dawn detergent, applied acid etch & Aldine
 
May 10, 2023     Cleanup - (4 hours) Category: Workshop
It had to be done.
 
May 09, 2023     White wings - (6 hours) Category: Paint / Decals
Applied 2 cross coats of AirTech CHSM Juneau White to both wings
 
May 08, 2023     Wing Gets Primed - (3.5 hours) Category: Paint / Decals
Shot left wing with AirTech epoxy primer. Acid etched and alodined small parts
 
May 05, 2023     More paint prep - (6 hours) Category: Workshop
Cleaned, etched & alodined numerous aluminum trim pieces
 
May 03, 2023     Mask & prime - (3 hours) Category: Paint / Decals
Masked fuel lines, tank & inspection openings; shot right wing with AirTech epoxy primer.
 
May 02, 2023     Wings - (9 hours)       Category: Paint Prep.
Watched, acid etched & alodined first wing.


 
May 01, 2023     Cleanup Day - (4 hours)       Category: Workshop
Cleaned up hangar and paint booth. Cleaned paint guns. Pulled plastic wrap off wings.


 
Apr 28, 2023     Touch up - (13.5 hours)       Category: Paint / Decals
Touched up paint on gear legs. Sprayed shock struts with AT white. Searched for parts. Remounted gear. (over 3 days)


 
Apr 25, 2023     Color coat aluminum parts - (2.5 hours)       Category: Paint / Decals
Shot two coats of AT white on boot cowl *& interior aluminum parts.


 
Apr 19, 2023     Primer: Boot cowl, etc. - (6 hours) Category: Paint / Decals
Primed boot cowl, interior aluminum panels.
 
Apr 18, 2023     Boot cowl & interior panels - (10 hours) Category: Paint Prep.
Washed, scuffed, acid etched & alodined boot cowl & interior aluminum panels.
 
Apr 14, 2023     More Do-overs - (9.5 hours)       Category: Paint Prep.
Cleaned up hangar & paint booth. Not happy with flaps, elevator & horizontal stab. Wet-sanded the whole lot & repainted with AT white.


 
Apr 13, 2023     Shiny Fuselage - (2 hours)       Category: Paint / Decals
Sprayed fuselage with 2 cross-coats of Air Tech white


 
Apr 10, 2023     More sanding - (4 hours) Category: Paint / Decals
Sanded fuselage primer in preparation for color (white) coat.
 
Apr 06, 2023     Prime Fuselage - (4 hours) Category: Paint / Decals
Primed fuselage with Air Tech fabric primer
 
Apr 04, 2023     Fuselage Prep. - (7.5 hours) Category: Paint / Decals
Over two days, prepped fuselage for priming
 
Apr 03, 2023     More Paint - (4 hours)       Category: Paint / Decals
Shot elevators, horizontal stabilizer & one of the flaps with white Air Tech


 
Apr 01, 2023     Door - (1.5 hours) Category: Paint Booth
Built a door for the paint booth.
 
Mar 31, 2023     Color Coat Part VII - (3 hours) Category: Paint / Decals
Shot 2nd coat, horizontals & gear legs.
 
Mar 28, 2023     Orange peel! - (10 hours)       Category: Paint / Decals
Wet sanded gear legs & control surfaces to knock down minor orange peel.


 
Mar 27, 2023     Fuselage - (2 hours)       Category: Paint Prep.
Touched up primer, masked critical areas on fuselage.


 
Mar 22, 2023     Color Coat, Parts IV-VI - (12 hours)       Category: Paint / Decals
Over 4 work days, continued 1sat color coat: flaps, ailerons, elevators & rudder


 
Mar 21, 2023     Color Coat, Part III - (3 hours)       Category: Paint / Decals
Shot second gear leg, elevator, flap & aileron


 
Mar 20, 2023     Color Coat, Part II - (3.5 hours) Category: Paint / Decals
Flipped gear leg & horizontal stab.; shot first coat, side 2.
 
Mar 17, 2023     Color (?) Coat, Part I - (4.5 hours) Category: Paint Booth
Shot 1one side gear leg & horizontal w. white "color" coat.
 
Mar 16, 2023     Paint's gotta shake. Man's gotta breathe. - (3.5 hours)       Category: Tools
Set up Hobby-Air system; set up paint shaker.


 
Mar 15, 2023     It's cold outside! - (2 hours) Category: Paint Booth
With temperatures hovering in the mid-thirties, and needing to keep the hangar door partially open to exhaust paint fumes, I hung poly sheeting along the bottom and in the open portion along the side. Duct tape is essential.
 
Mar 13, 2023     New Tools       Category: Paint Prep.
Cleaned and set up new HVLP spray gun.


 
Mar 08, 2023     Clean-up - (2 hours) Category: Workshop
Sweep, haul trash.
 
Mar 06, 2023     Fuselage and Paint Booth - (5.5 hours)       Category: Paint Prep.
Continued sanding primer--on to the fuselage. Cleaned up paint booth.


 
Mar 01, 2023     Sanding continues - (10.5 hours) Category: Paint Prep.
Over 3 work days, continued sanding primer on control surfaces.
 
Feb 28, 2023     Sand, rinse, repeat - (2 hours)       Category: Paint Prep.
After curing for several months, the primer cried out for sanding. Blue masking tape defines and protects underlying hard surfaces (tubing, etc.).


 
Feb 27, 2023     Cleanup - (3 hours) Category: Workshop
On returning to work after four4 months, I found my hangar in complete disarray. I don't get it.
 
Feb 21, 2023     Review - (1.5 hours)       Category: Research
Before I get back to painting, I thought it prudent to do a little review. Watched EAA webinar on spraying paint with Ron Alexander. c. 2010.


 
Jan 02, 2023     New Zealand Sojourn Continues       Category: R&R
Taking a break….


 
Nov 14, 2022     Taking a break Category: R&R
Off to New Zealand for some extended trout therapy
 
Sep 22, 2022     FUSELAGE. 1ST COAT - (4 hours) Category: Paint / Decals
BROKE DOWN PAINT GUN & CLEANED TH0ROUGHLY. SPRAYED FUSELAGE 1ST COAT PRIMER. IN & OUT
 
Sep 20, 2022     FUSELAGE PREP. - (3.5 hours) Category: Paint Prep.
CONTINUED MASKING FUSELAGE
 
Sep 19, 2022     PAINT BOOTH EXPANSION - (2 hours) Category: Paint Booth
EXTENDED LENGTH OF PAINT BOOTH BY 24 INCHES.
 
Sep 17, 2022     PREP FUSELAGE - (3 hours)       Category: Paint / Decals
Clean Up fabric & mask where needed in preparation for first primer coat.


 
Sep 16, 2022     SAND, CLEAN, PRIME - (4 hours) Category: Paint / Decals
SAND, CLEAN UP DUST, & SPRAY PRIMER THROUGH3RD COAT: CONTROL SURFACES
 
Sep 15, 2022     SAND, CLEAN, & SPRAY - (4 hours)       Category: Paint / Decals
SAND, CLEAN UP DUST, & SPRAY PRIMER THROUGH 2ND COAT: CONTROL SURFACES


 
Sep 14, 2022     PRIMER: FLAPS & AILERONS - (4.5 hours)       Category: Paint / Decals
SHOT FLAPS & AILERONS W. FIRST COAT OF PRIMER


 
Sep 13, 2022     PRIMER: TAIL FEATHERS - (3 hours)       Category: Paint / Decals
SHOT THE RUDDER, HORIZONTAL & ELEVATOR W. PRIMER


 
Sep 12, 2022     PRACTICE - (3 hours) Category: Paint Prep.
SET UP SPRAY GUN & PRACTICED ON CARDBOARD, SCRAP SHEET METAL, ETC.
 
Sep 08, 2022     CLEANUP - (3 hours) Category: Paint Prep.
VACUUMED DUST, WIPED DOWN SURFACES, CLEANED UP EQUIPMENT IN PREPARATION FOR FIRST PRIME COAT
 
Sep 07, 2022     Paint Prep - (4 hours) Category: Paint Prep.
Cleaning & trimming fabric as needed prior to painting---
 
Sep 01, 2022     Escape hatch - (4 hours) Category: Paint Booth
Attached a door of sorts to entry area, just large enough to roll fuselage or wings in and out.
 
Aug 31, 2022     Clean Air - (2 hours) Category: Paint Booth
Framed openings at the top of the booth for 4 furnace filters. Will experiment with various combinations of fan speed and number of filters to determine what works best.
 
Aug 29, 2022     Fans - (3 hours)       Category: Paint Booth
Added three 20" box fans to pull air out of the booth.


 
Aug 26, 2022     Rotisserie - (5 hours) Category: Tools
Hard to believe, but it took the better part of the day to replace the casters on the rotisserie!
 
Aug 22, 2022     Carpentry - (11 hours)       Category: Paint Booth
Laid out, framed and covered paint booth with 6 mil. poly. Used one side of hangar for wall.. Hung 12 led light strips on side and top.


 
Aug 19, 2022     Cleanup - (4 hours) Category: Workshop
Swept up, organized tools and got ready to build a paint booth.
 
Aug 15, 2022     Back to the Boot Cowl! - (17.5 hours) Category: Paint Prep.
Cleaned up and checked boot cowl for burrs. Removed plastic wrap. Replaced short section at the bottom to get a better fit.
 
Aug 04, 2022     Lots of Plastic - (9.5 hours) Category: Paint Prep.
Checked aluminum & steel parts for burrs I might have missed. Missed quite a few. Deburred as I went. Removed many square feet of plastic from aluminum, as I prepare for priming and paint.
 
Aug 03, 2022     Door Trim - (3 hours) Category: Fuselage
Cleaned up door frames. Drilled to 1/8". for rivets.
 
Aug 02, 2022     Window Frames.2 - (5 hours)       Category: Windows
Cleaned up window frames. Drilled to 1/8" for rivets


 
Jul 29, 2022     Cleanup - (2 hours) Category: Workshop
Short day. Put away tools, modified one of my shop carts, clocked out early.
 
Jul 29, 2022     Window in the Door - (2 hours)       Category: Windows
Fit a plexi window in lower section of the door. It won't be terribly useful for the pilot, but will give the passenger in the rear seat a better view.


 
Jul 26, 2022     Window Trim - (4 hours) Category: Windows
Finished preliminary fit on side windows. Will trim and number all the pieces prior to cleaning and prepping for paint.
 
Jul 25, 2022     Window trim, continued - (2 hours) Category: Windows
Continued fitting trim pieces on side windows.
 
Jul 21, 2022     Window trim, continued - (5 hours)       Category: Windows
Continued fitting window trim pieces. (Next time, I'll build my own frames, and use square, not round tubing!


 
Jul 20, 2022     Yard Work - (2 hours) Category: Workshop
Two hours driving the lawn mower around my hangar (and my neighbor's)
 
Jul 20, 2022     Window Frames.1 - (2 hours)       Category: Windows
Resumed work on fitting .025 aluminum window frame pieces. As the manual and plans provide little guidance, this was a trial and error process. Sadly, more error than trial at times!


 
Jul 19, 2022     Town Run - (4 hours) Category: Paint Booth
Drove into Missoula to secure 2X4, polyethylene sheeting, box fans, air filters for paint booth.
 
Jul 18, 2022     Cleaning Day - (4 hours) Category: Workshop
Once again, time to put tools and supplies in their places, sweep & tidy up.
 
Jul 16, 2022     Gear Legs.5 - (1.5 hours) Category: Covering
Ironed finish tapes
 
Jul 15, 2022     Gear legs.4 - (3 hours) Category: Covering
Applied finish tape and attached inspection rings @ brake line fittings.
 
Jul 14, 2022     Gear legs.3 - (6 hours) Category: Covering
Finished covering g. legs. Shrunk fabric @ 250-300-350. Marked and laid down adhesive for finish tapes.
 
Jul 13, 2022     Gear legs.2 - (6 hours) Category: Covering
Applied Ceconite on gear legs.
 
Jul 12, 2022     Gear Legs - (2 hours) Category: Covering
laid down 2 coats of thinned adhesive (2:1) at attach points on gear legs
 
Jul 11, 2022     Ironing.2 - (7 hours) Category: Covering
Continued ironing finish tapes.
 
Jul 09, 2022     Ironing - (3 hours) Category: Covering
Began ironing finish tapes using 250 F iron.
 
Jul 08, 2022     Fuselage Tapes - (6 hours)       Category: Covering
Continued applying tapes to fuselage @ wear points.


 
Jul 07, 2022     Finish Tapes - (5 hours) Category: Covering
Began marking glue lines for finish tapes @ formers and longhorns.
 
Jul 07, 2022     More shrinking; Rotisserie Revisited - (5.5 hours)       Category: Covering
Shrink bottom fabric @. 250-300-350. Began rebuilding a rotisserie using 1" pipe flanges &. 2X4's.


 
Jul 06, 2022     Rotisserie - (3 hours)       Category: Covering
Mounted fuselage on rotisserie @ firewall. Removed landing gear.


 
Jul 06, 2022     Finish Tapes - (4 hours) Category: Covering
Finished applying tapes on top & sides of fuselage
 
Jul 05, 2022     Finish tapes.6 - (5 hours) Category: Covering
Continued with tapes
 
Jul 01, 2022     Finish Tapes.5 - (6 hours) Category: Covering
Began applying finish tapes @ all (potential) wear points on fuselage, beginning with vertical stab.
 
Jun 28, 2022     Finish Tapes.4 - (5 hours) Category: Covering
Continued applying thinned glue (2 coats) for finish tapes at all wear points
 
Jun 27, 2022     Finish Tapes.3 - (6 hours) Category: Covering
Applied adhesive @ vertical stab. & top- of fuselage in preparation for finish tapes.
 
Jun 24, 2022     Finish Tapes.2 - (3 hours) Category: Covering
Continued marking glue lines
 
Jun 21, 2022     Bottom side & cable fairings - (4.5 hours)       Category: Covering
Glued fabric to bottom of fuselage. Used 1/2" magnets to hold fabric to longerons. Much easier than spring clamps.
Glued fairings @ cable exit points.


 
Jun 20, 2022     Inspection Openings, Glue, Call Fairings - (5 hours)       Category: Covering
Cleaned up the fabric around inspection openings. Applied 2 coats of thinned adhesive on bottom longhorns, in preparation for attaching fabric on bottom. Primed cable fairings.


 
Jun 18, 2022     Cleaning Day - (3 hours) Category: Workshop
Tools everywhere! Time to put things away and sweep up.
 
Jun 17, 2022     Trim and fit - (3 hours)       Category: Covering
Continued cleaning up around the edges


 
Jun 17, 2022     More trimming Category: Covering
 
Jun 16, 2022     Inspection opening - (4 hours)       Category: Covering
Glued .020 frame @ horizontal stab. location. Both sides. Will provide access for install and inspection of elevator & trim control attach points.


 
Jun 15, 2022     inspection plates - (4 hours)       Category: Covering
Researched and fabricated backing plates for access openings @ horizontal stabilizer.


 
Jun 14, 2022     Trim and fit - (3 hours) Category: Covering
Worked around the fuselage, trimming fabric as needed.
 
Jun 13, 2022     Throttle - (2 hours) Category: Controls
Reinstalled connecting rod between fore and aft throttles. Would have been much easier before I glued the fabric on!
 
Jun 10, 2022     Static Ports - (2 hours)       Category: Instruments
Attached static ports on both sides. Glued . 020 aluminum ring on inside as backing plate.


 
Jun 09, 2022     Throttle Linkage - (3 hours) Category: Controls
Having repositioned the front and rear throttle quadrants, I found that the linkage was now too short! Threaded a new section of 3/16" steel rod to accommodate clevis forked ends.
 
Jun 09, 2022     Final Shrink - (3 hours)       Category: Covering
Continued shrinking. Iron @ 350 F.


 
Jun 08, 2022     More shrinking - (6 hours)       Category: Covering
Continued shrinking. Iron @ 300 F


 
Jun 07, 2022     Incredible Shrinking Ceconite - (7.5 hours)       Category: Covering
Shrunk fabric top & sides using 250 F iron. Glued fabric to left forward section (pilot cockpit).


 
Jun 06, 2022     Top & Sides - (6.5 hours)       Category: Covering
Attached semi-envelope to top and sides. Glue @ bottom longerons. Fitting fabric into rear window channels was tedious, but not especially difficult.


 
Jun 04, 2022     Fuselage Envelope - (4 hours)       Category: Covering
Fit and glued fabric @ rear windows. Fabric is inserted in channel such that window will trap it, in addition to the glue. 3/4 x 1/16 aluminum bar, rounded at corners, makes a nice tool for fitting the fabric into the channels.


 
Jun 03, 2022     Reinforcement & patches - (3 hours) Category: Covering
Cut and fit patches and reinforcements at strategic areas, interior fabric.
 
Jun 03, 2022     Static lines - (2 hours)       Category: Instruments
Located static ports, joined left & right lines to single line using Nyla-Seal T-fitting.


 
Jun 02, 2022     Glue - (3 hours) Category: Covering
Applied Air Tech UA 55 to rear window frames, top former, and longhorns in preparation for installing fuselage fabric. Began gluing fuselage envelope, starting with the "backbone". or top former and vertical stab.
 
May 31, 2022     Front windows - (6 hours)       Category: Windows
Began assembling front windows. Cut and fit polycarbonate sheet, drilled and secured frame pieces with Clecos.


 
May 30, 2022     Rear Windows.1 - (7.5 hours)       Category: Windows
Marked and cut polycarbonate sheet for rear windows. Fine-toothed jig saw worked fine.


 
May 28, 2022     Static lines - (4 hours) Category: Instruments
Ran static line under floor. Temporarily secured with zip ties. Will replace with Adel clamps. Located static ports on either side, lower fuselage.
 
May 28, 2022     Static lines - (4 hours) Category: Research
Reviewed sources on placement of static ports and line. Purchased 25 fee of 1/4" polyethylene tubing. Sourced Nylo-seal fittings.
 
May 25, 2022     Skylight frame - (6.5 hours)       Category: Windows
Added nut plates at rear of skylight frame. Tight fit in a couple places led to temporary modification of rivet squeezer, using a machine screw & hex nut. Not very pretty, but it worked.


 
May 24, 2022     Right side fabric - (8 hours) Category: Interior Finish
Fit and glued fabric, right side.
 
May 23, 2022     Right rear panel, continued - (5 hours) Category: Interior Finish
More nut plates and Adel clamps to anchor panel.
 
May 20, 2022     Right side panel - (5 hours)       Category: Fuel System
Fit aluminum panel below right rear window--more for appearance than function, though, anticipating that the passenger area will likely often be used for hauling baggage and equipment, it seems worth the addd weight.


 
May 19, 2022     Relocate fuel line - (5.5 hours)       Category: Fuel System
As I shrunk the interior fabric, I notice that the forward section of the right fuel line was routed through the interior of the cabin, and could potentially interfere with the rear rudder pedal. Cut out the lower section and re-routed to the outside with an angled union through the top former.


 
May 18, 2022     Interior fabric. - (6 hours) Category: Interior Finish
Began shrinking fabric (250-300-350). Not satisfied with fabric in passenger area. Replaced and overlapped front piece. (2" overlap over tubing)
 
May 17, 2022     Interior Fabric - (4 hours) Category: Interior Finish
More fabric and glue. Fit is getting more precise as I learn, but I'll need to patch in a number of places where the fabric goes around tubes at odd angles.
 
May 16, 2022     More interior fabric - (7 hours)       Category: Interior Finish
Fit and glued fabric to interior, ceiling and lower sides, using Air Tech adhesive.


 
May 11, 2022     Dry-fit fabric - (8 hours)       Category: Interior Finish
Cut and dry-fit fabric prior to adhesive application.


 
May 09, 2022     Nut plates and fabric work. - (7 hours)       Category: Interior Finish
Mark, drill, deburr, etc. Attaching panels with machine screws and nut plates in order to facilitate inspection and adjustment of throttle & trim controls. Began fitting fabric to interior


 
May 05, 2022     Side panels - (11 hours) Category: Interior Finish
(Portions of 3 days) continued trimming and fitting the panels. it's not a lot of surface, but lots of stuff to cut around.
 
May 04, 2022     Side panels - (4 hours)       Category: Interior Finish
Continued fitting and trimming panels. Will acid etch and Alodine prior to painting.


 
May 03, 2022     Side panels - (8 hours)       Category: Interior Finish
Panels will be anchored to 3/4' aluminum angle. Sheet metal skills are improving, but very slowly. The new 36" brake is most helpful, though the sharp edges cry out for some file work.


 
May 02, 2022     Side panels - (6 hours)       Category: Interior Finish
Continued fitting the aluminum panels along the left side of the cockpit.


 
Apr 30, 2022     Design Changes Have Consequences - (33.5 hours) Category: Interior Finish
I learned to fly in a Citabria, which has the trim control on the left side, below the throttle. Mr. Barrows designed the Patrol with the trim control above and behind the pilot's head. Just didn't work for me, so I moved it. As a result, I have cables running along the left side of the cockpit, front and rear, all the way back through the baggage compartment. Seemed like a control jam situation waiting to happen. So, I've spent the last few weeks fabricating aluminum panels to protect the cables, and prevent a future inconvenience. Many re-dos, as the design develops. (photos to follow in a future post.
 
Apr 11, 2022     Cleanup - (2 hours) Category: Workshop
When I find myself making more than 3 circuits of the hangar to find a particular tool, it's time to put everything away, sweep up, and start with a clean shop!
 
Apr 02, 2022     Metal Prep - (11 hours) Category: Fuselage
Removed aluminum parts. Scuffed with Scotchbrite pad, Acid etched and alodined, using Bonderite C-IC 33 and Bonderite M-CR 1201 AERO.
 
Apr 02, 2022     Bootcowl. v. 4.0 - (31 hours)       Category: Bootcowl
Among the tasks I left undone was the installation of a few dozen nut plates for attaching the boot cowl. Although some builders simply rivet the BC and make it permanent, I'd like to keep as much of the airplane accessible for as long as I can. Also trimmed the BC at the rear where it will meet fabric. (7 work days)


 
Mar 19, 2022     Cleanup - (1.5 hours) Category: Workshop
Just a quick sweep and take out the trash!
 
Mar 17, 2022     Supply run - (3 hours) Category: Windows
Trip to Lowe's for a sheet of polycarbonate and some drill bits.
 
Mar 15, 2022     4th Time's the Charm? - (16 hours)       Category: Bootcowl
Although I had the boot cowl essentially complete months ago, a few taskes remained. I fit a small piece at the cutout around the cabane struts. This will attach to a doubler via nut plates and screws. Drilled, deburred, dimpled, etc. (3 work days)


 
Mar 09, 2022     Window Frames - (19 hours)       Category: Windows
Built a jig to hold the window frames steady as I measured, drilled, deburred, checked the many thin strips of aluminum that make up the window frames on both sides of the cockpit. Based on the plans and many photos of completed Bearhawks, it's clear that the plexiglass is sandwiched between the trim pieces and the tubular window frames. it's so simple it had me severely confused! (4 work days)


 
Mar 07, 2022     Protecting Controls.2 - (10 hours)       Category: Interior Finish
Continued fitting and adjusting the side panel that will protect the trim cables and rod connecting fore and aft throttle controls. (2 work days)


 
Mar 01, 2022     Protecting the Controls - (14 hours)       Category: Interior Finish
Continued work on the .025 panel on the left side . Fabricated several L-shaped brackets with nut plates attached. These were attached to fuselage tubing with Adel clamps. The shroud ended up a two-piece affair. The inner piece was bent at the edges to add stiffness, and will anchor the fabric at the bottom. the top piece will be covered with Ceconite to match the rest of the interior. Using a small router,mounted on a pivoting base, I cut an arc in the top piece to fit around the trim control. (3 work days)


 
Feb 28, 2022     Side Panel - (5 hours)       Category: Interior Finish
Made a couple adjustments to the original design to better accommodate removal for inspection. Cut and fit the panel. Will add inspection holes at quadrants, inside and out.


 
Feb 26, 2022     Off Again - (2 hours) Category: Wings
With the help of neighbors Don and Mel, got the wings off and onto the new stand. (Fuselage now much easier to reposition!)
 
Feb 25, 2022     Wing Stand - (8 hours)       Category: Tools
Using plans from Sport Aviation archive, built a rolling wing stand.


 
Feb 24, 2022     Pre-Cover preparation.2 - (6 hours) Category: Interior Finish
Fabricated a mockup of a .025 panel to protect throttle linkage and trim cables @ left side.
 
Feb 23, 2022     Pre-Cover preparation - (6 hours) Category: Fuselage
Using pasteboard templates, and old bedsheet, and scraps of Ceconite, I practiced fitting fabric at various points in the cockpit area. Looks like lots of notching and fitting. Should be fun.
 
Feb 22, 2022     Windows & Doors - (2 hours) Category: Fuselage
Researched fit & trim options for installing doors and windows.
 
Feb 22, 2022     Pre-Cover preparation - (2 hours) Category: Fuel System
Repositioned the right-side fuel line at the corner of the windscreen, installed remaining flex. lines.
 
Feb 16, 2022     Trim System Reboot.6 - (20 hours)       Category: Controls
20 hours over four days--refabricated my trim control--repositioned the quadrant, made a new, lighter weight lever.


 
Feb 14, 2022     Trim System Reboot.5 - (5 hours)       Category: Controls
On reading several accounts by other builders, I learned that the trim on the Bearhawks tends to be much more sensitive than needed. Based on their recommendations, I lengthened the trim horn in order to reduce the rate of movement. (longer arm = less rotation of torque tube = less movement of pushrod = less movement of trim tab.


 
Feb 11, 2022     Trim System Reboot.4 - (5 hours) Category: Controls
More work on the aft portion of the trim system. Today's hours include a lengthy "consultation" with a hangar-neighbor.
 
Feb 10, 2022     Trim System Reboot.3 - (3 hours) Category: Controls
Continuing with the trim torque tubes.
 
Feb 09, 2022     Trim System Reboot.2 - (2 hours) Category: Controls
Continued re-aligning the torque tube--process involves removing & re-installing both the horizontal stabilizer and elevators...again and again! There's not a whole lot of room at the point where trim and elevator controls get down to business, so I'm taking extra pains to avoid any possibility of a jam back there!
 
Feb 07, 2022     Trim System Reboot.1 - (3 hours) Category: Controls
Continued work resigning trim actuator torque tube.
 
Feb 05, 2022     Cleaning Day - (1.5 hours) Category: Workshop
Swept, put away tools, made a hardware run
 
Feb 04, 2022     Notebooks - (2 hours) Category: Workshop
Spent a couple hours organizing my various binders--Engine--Avionics /Wiring--etc.
 
Feb 04, 2022     Trim actuators - (4 hours) Category: Controls
Pulled the trim torque tubes and began the process of realigning the fittings to avoid contact with elevator actuators.
 
Feb 03, 2022     Pre-Cover Details - (2 hours)       Category: Covering
Cut templates to assist in locating rudder cable exit holes @ rear of fuselage.


 
Jan 18, 2022     FUEL GAUGE.1 - (5.5 hours)       Category: Fuel System
TEMP. CONNECTED FUEL LINES FROM WINGS TO FUSELAGE @ WING ROOT. USED 3/8" SUPER FLEX FUEL LINE HOSE, BEADED TUBING @ JUNCTION & HOSE CLAMPS
FABRICATED LEFT SIDE FUEL GAUGE; WILL ADD SUPPORT USING ADEL CLAMPS. NEED TO INSERT PLASTIC BALL BEFORE FINAL INSTALL.


 
Jan 17, 2022     MORE BRAKE LINES - (8.5 hours) Category: Brakes
COMPLETED THE FLEX. LINES (AEROQUIP 303) FROM THE MASTER CYLINDERS AND PARKING BRAKE VALVES TO THE GEAR LEGS.
 
Jan 11, 2022     Parking Brake & Reservoir - (5 hours)       Category: Brakes
Temporarily installed brake fluid reservoir on the hot side of the firewall. Temporarily attached parking brake valve on the aft side. Spent quite a while looking for items stashed before my break and sorting out the various sizes of the required AN fittings.


 
Jan 10, 2022     Gotta Stop - (6 hours)       Category: Brakes
Following an extended search for a missing fitting, I reattached the fluid lines in the gear legs. I then assembled, using the manufacturers instructions, a 13" flexible line (Aeroquip 303) to run from the master cylinder to the gear leg.


 
Jan 04, 2022     Reassembly - (2 hours)       Category: Controls
Reassembled elevator; trial fit re-covered trim tabs. Note: still a very tight fit.


 
Nov 19, 2021     Time Out       Category: Research
Taking a break. Back in six weeks!


 
Nov 18, 2021     Trim - (3 hours) Category: Controls
Repositioned trim control to a more comfortable position.
 
Nov 17, 2021     Finish Tape 2.0 - (10 hours) Category: Tail Feathers
Applied finish tape to elevators over 3 days and 10 hours.
 
Nov 10, 2021     Re-Do - (5 hours) Category: Fuel System
Re-worked the fuel lines in the fuselage. I was not happy with the alignment or straightness of the tubing.
 
Nov 01, 2021     FLAPS - (5 hours)       Category: Wings
Fabricate Flap Hinge 1/8” steel
Fabricate bushings: 3/16 -> �
Attach flap springs
Order parts


 
Oct 31, 2021     FLAP HINGE - (2 hours) Category: Wings
Fabricate Flap Hinge
2
 
Oct 29, 2021     FLAPS 5 - (5 hours) Category: Wings
Iron finish tape: flap center bay
 
Oct 27, 2021     FLAPS - (4 hours) Category: Wings
Iron finish tape: flap center bay
 
Oct 26, 2021     CLEANUP - (1 hour) Category: Workshop
Shop cleanup
 
Oct 26, 2021     FLAPS - (4 hours) Category: Wings
Re-cover center flap bay per Airtech manual and AC43.13—1A
 
Oct 25, 2021     FLAPS - (3 hours)       Category: Wings
10/25/2021
Reattach flap hinges using new AN hardware
Open center flap bay and replace defective nutplate
3


 
Oct 22, 2021     SKYLIGHT FRAME - (4 hours)       Category: Fuselage


Fabricate frame for skylight using kit parts and ��uminum angle



 
Oct 20, 2021     Skylight FRAME - (4.5 hours) Category: Fuselage
Fabricate frame for skylight using kit parts and ��inum angle
 
Oct 20, 2021     Aluminum - (1 hour) Category: Research

Research preparation of aluminum pre-paint

 
Oct 14, 2021     Window Frames - (8 hours)       Category: Fuselage



Attach frames for rear windows



 
Oct 13, 2021     Fabric: Fuselage - (6 hours)       Category: Fuselage
Trim fabric—fuselage
Re-hang ailerons
Research window placement



 
Oct 12, 2021     Fabric--Fuselage       Category: Fuselage
Measure and fit fabric—fuselage
Mark seam @ top center stringer w. straight pins
Reattach hinges—ailerons
5


 
Oct 07, 2021     Ailerons - (6.5 hours)       Category: Controls
Re-cover trim tabs
Iron finish tapes—ailerons
Prime hinges—ailerons and flaps


 
Oct 06, 2021     Dynon - (2 hours) Category: Research
Review Dynon Installation manual
 
Oct 05, 2021     Finish Tapes - (4 hours)       Category: Covering

Re-do finish tapes-elevators
Install center stringer


 
Oct 04, 2021     Elevators - (4 hours) Category: Covering

Attach and iron finish tapes—elevators

 
Sep 16, 2021     Rib-Stitching - (13 hours) Category: Tail Feathers
Rib-stitched elevators over 2 days and 13 hours.
 
Sep 14, 2021     Re-Cover - (11 hours) Category: Tail Feathers
RE-covered both elevators over two days and 11 hours.
 
Sep 08, 2021     Trim Actuatorsators - (5 hours) Category: Tail Feathers
Reassembled elevators/hor. stab. to confirm locations of trim actuators. Drilled actuator tube and bell crank.
 
Sep 06, 2021     Clean-up - (3 hours) Category: Tail Feathers
Removed fabric from horizontal stabilizer and elevators. Cleaned up glue residue using acetone.
 
Sep 01, 2021     Trial Fit - (4 hours) Category: Tail Feathers
With the tail feathers finish-taped, I attempted to re-assemble the tail, only to find that the gap between the horizontal. stabilizer and elevators is so tight that, having doubled the fabric around the frame, I could no longer fit the pieces together. Lesson learned. I will strip the fabric and re-cover, using a single fold at the gap.
 
Aug 31, 2021     Trim actuators - (5 hours)       Category: Covering
Opened skin to accomodate the trim actuators on both sides of the horizontal stabilizer. Will add slotted aluminum cover before prepping for paint. Completed finish tapes on tail feathers


 
Aug 30, 2021     Finish Tape - (4.5 hours)       Category: Wings
Applied finish tape, both ailerons


 
Aug 26, 2021     Tail Feathers.3 - (10 hours) Category: Covering
More marking and finish taping over two days
 
Aug 25, 2021     Tail Feathers.2 - (7 hours)       Category: Covering
Continued with finish tape on tail feathers-


 
Aug 23, 2021     Tail Feathers - (2.5 hours)       Category: Covering
Marked and taped tail feathers.


 
Aug 13, 2021     Finish Tapes - (18.5 hours)       Category: Covering
Marked & taped finish tapes over rib stitching--ailerons & elevators---over 4 days and 18.5 hours


 
Aug 09, 2021     More rib stitching - (18.5 hours)       Category: Covering
Took a little road trip to the east coast. Having gotten that out of my system, returned to the important work of rib stitching the horizontal stabilizer and rudder-18.5 hours over three days.


 
Jul 13, 2021     Rib stitch - (9 hours)       Category: Covering
Over two days, prepped and rib stitched tail feathers.


 
Jul 09, 2021     Tail Feathers - (14 hours) Category: Covering
Over three days, ironed tail feathers. @ 250, 300, 375 degrees
 
Jul 05, 2021     more tape - (9.5 hours) Category: Covering
Finish tape ailerons and flaps
 
Jul 04, 2021     Tape - (7 hours) Category: Covering
Applied finish tape to flaps
 
Jul 03, 2021     Tape & Iron - (6 hours) Category: Covering
Finish tape & iron ailerons
 
Jun 23, 2021     Ailerons - (4.5 hours) Category: Covering
Finish tape on ailerons.
 
Jun 22, 2021     Shrinking Fabric - (3 hours) Category: Wings
Shrunk fabric, ailerons & flaps. at 250, 300, 375 F. per AirTech manual
 
Jun 21, 2021     Covering - (3 hours)       Category: Wings
Covered right flap


 
Jun 18, 2021     Covering - (3 hours)       Category: Wings
Covered right aileron


 
Jun 17, 2021     Covering - (2.5 hours) Category: Wings
Covered left aileron
 
Jun 16, 2021     Covering - (4 hours) Category: Wings
Covered ends of ailerons and flaps
 
Jun 15, 2021     Covering - (4 hours) Category: Wings
Applied 2 coats of UA 55 (AirTech adhesive) to flap & both ailerons. Began shrinking fabric on flap using iron @ 250 . per AirTech manual.
 
Jun 14, 2021     Cover Prep - (2.5 hours) Category: Wings
Prepped aileron & flap for covering
 
Jun 11, 2021     Cover Flaps - (4 hours) Category: Wings
Covered left flap w. Ceconite per AirTech manual.
 
Jun 10, 2021     Flaps - (3.0 hours) Category: Wings
Cleaned hangar; prepared flaps for cover; reviewed cover procedures.
 
Jun 09, 2021     Flaps - (3 hours) Category: Wings
Attach trailing edge, right flap
 
Jun 03, 2021     Flaps - (5 hours) Category: Wings
Attached trailing edge to left flap; aligned left flap & aileron
 
Jun 02, 2021     Ailerons - (3.0 hours) Category: Wings
Attached trailing edge, right aileron w. pulled SS rivets.
 
Jun 01, 2021     Bootcowl/Windscreen - (2.5 hours)       Category: Fuselage
Attached boot cowl to fuselage with clicos ; test-fit windscreen


 
May 29, 2021     Hanging Wings.1 - (4 hours)       Category: Wings
With the assistance of three neighbors, got the wings mounted for the first time.


 
May 28, 2021     Wing Stand - (4 hours)       Category: Workshop


 
May 27, 2021     Nose stand - (3 hours)       Category: Workshop
Built a stand to support front of fuselage via pivot attached yesterday.


 
May 26, 2021     Tail Stand and Attachment point for firewall - (3.5 hours)       Category: Workshop
Built a tail stand to assist in leveling fuselage. Built a pivot & attached to firewall to assist in rotating fuselage during covering.


 
May 25, 2021     Fasteners - (1 hour) Category: Research
Reviewed FAA AC. 14.13 1B, Chapter 7--Hardware. Bring to determine appropriate fasteners for boot cowl, especially as pertains to access to avionics, etc.
 
May 24, 2021     Fabric - (2 hours) Category: Research
Reviewed AirTech manual & videos on covering fuselage.
 
May 22, 2021     Bootcowl Reboot 3.0 - (4 hours) Category: Bootcowl
BC largely finished. Wlll add rubber boots around gear legs once engine is installed and gear is aligned.
 
May 21, 2021     Bootcowl.Bottom - (4 hours) Category: Bootcowl
Nibbling aluminum in tiny increments to fit bc around gear legs.
 
May 20, 2021     Bootcowl.Bottom - (5 hours) Category: Bootcowl
Continuing work on underside of boot cowl.
 
May 19, 2021     Bootcowl Reboot 3.0 - (2.5 hours)       Category: Bootcowl
Continuing to fit boot cowl around gear legs


 
May 18, 2021     Bootcowl Reboot 3.0 - (4 hours)       Category: Bootcowl
In its third iteration, the greater part boot cowl is cut from a single piece of aluminum.


 
May 17, 2021     Bootcowl Reboot 3.0 - (3 hours) Category: Bootcowl
Continued work on fitting boot cowl.
 
May 15, 2021     Re-Boot, Continued - (3 hours)       Category: Bootcowl
Getting Close. Trying to get close to gear attach points, while allowing for movement.


 
May 14, 2021     Re-Boot, Continued - (4 hours) Category: Bootcowl
Began slowly tracing/cutting .025 661T4 aluminum sheet to fit around cabane struts, gear legs, etc.
 
May 13, 2021     RE-Boot, Continued - (4 hours) Category: Bootcowl
Lots of cutting and taping, as I attempt to get a tight fit for the pattern. Tomorrow, I start cutting aluminum.
 
May 12, 2021     Re-Boot, Continued - (3 hours)       Category: Bootcowl
Continued mockup with poster board


 
May 11, 2021     Do-Over Part 2 - (4 hours) Category: Fuel System
Continued work on re-routing fuel lines.
 
May 10, 2021     Do-Over - (3.5 hours) Category: Fuel System
Rerouted fuel lines from doorframes to fuel selector to eliminate chafing.
 
May 08, 2021     Parts Order - (1.5 hours) Category: Landing Gear
Ordered tubing & Aeroquip fittings along with a ferule for assembling brake lines.
 
May 07, 2021     Brakes - (4 hours)       Category: Landing Gear
Worked out schematic for brake system.


 
May 06, 2021     Brake System Design - (4 hours) Category: Research
Sketched & re-sketched the design for the brake system.Came up with the simplest layout I could.
 
May 06, 2021     Brakes - (2.5 hours) Category: Research
Spent some time with the manuals, forums, and books, sorting out the parts and pieces of what is really an uncomplicated system.
 
May 06, 2021     Research: Brake system - (2.5 hours) Category: Research
Consulted the Bearhawk forums, Tony Bingelis, et. al. regarding choices and configurations of brake lines.
 
May 05, 2021     Bootcowl Reboot 3.0 - (6 hours)       Category: Bootcowl
Unhappy with the boot cowl. Suspect perfectionism creeping in, but under control so far. Started with a new piece of .025 aluminum, and took it slow@


 
May 05, 2021     Bootcowl Reboot 3.0 - (6 hours)       Category: Bootcowl
Still not happy with the looks of the bootcowl. First and second versions simply had too many pieces, too many screws and nut plates. Accordingly, I've gone back to the pasteboard stage, and will try to fabricate a single piece for the top and sides, with a removable section in the center to accommodate the cabane struts.


 
Apr 30, 2021     Throttle - (2.5 hours) Category: Controls
Reworked throttle attachment @ left side cockpit
 
Apr 29, 2021     Gussets - (5 hours)       Category: Wings
Attached gussets to ailerons & flaps; ordered parts


 
Apr 29, 2021     Aileron Hinges - (6 hours) Category: Workshop
Not happy with fit and function of aileron hinges. Replaced with parts cut from rejected flap hinges.
 
Apr 27, 2021     Maule Therapy - (1 hour)       Category: Workshop
Took a break for a brief flight in the Maule. Gave the hangar a much-needed cleaning.


 
Apr 24, 2021     Gussets - (4 hours) Category: Wings
Attached gussets and trailing edges on ailerons & flaps
 
Apr 24, 2021     Throttle, revisited - (2.5 hours)       Category: Controls
On inspecting the throttle quadrant install, I discovered the need for castigated nuts in several areas, which led to some additional drilling and fitting of the mounting bracket. While I was at it, I drilled a few lightening holes in the 1/8" aluminum plate.


 
Apr 23, 2021     Didn't see this coming - (2 hours)       Category: Wings
With gussets reinstalled, it was time to realign the trailing edges, which are rolled so tightly that it's impossible to get a regular dimple die between the halves in order to install flush rivets. Ordered special pulled rivet dies & additional rivets.


 
Apr 22, 2021     Ailerons & Flaps - (5 hours) Category: Wings
More work on gussets--Squeezed rivets where the squeezer would fit; pull rivets where there was insufficient clearence.
 
Apr 21, 2021     Ailerons & Flaps - (4 hours)       Category: Wings
Continued with gussets.


 
Apr 20, 2021     Ailerons & Flaps - (5 hours)       Category: Wings
Began replacing gussets on ailerons & flaps, using CCC-32 &
CCC-34 pull rivets/


 
Apr 20, 2021     Covering Video - (2 hours) Category: Research
Reviewed AirTech video (YouTube) on covering process.
 
Apr 16, 2021     Ailerons & Flaps - (5 hours) Category: Wings
Drilled hinge plates & installed nut plates on spars.
 
Apr 15, 2021     Ailerons & Flaps - (5 hours) Category: Workshop
More trial & error, clamp & reclamp. Now ready to drill.
 
Apr 12, 2021     Ailerons & Flaps - (4 hours) Category: Wings
Began fitting hinges to second wing. Familiar territory now, so work moving a bit more quickly.
 
Mar 25, 2021     Creeper modification - (4 hours)       Category: Workshop
In an effort to save my back, I built an adjustable seatback for my creeper. Not pretty, but makes a huge difference when working under the fuselage or a table-mounted wing!


 
Mar 24, 2021     Ailerons & Flaps - (06 hours)       Category: Wings
Installed nut plates on spars of aileron & flap to receive hinge plates.


 
Mar 23, 2021     Ailerons & Flaps       Category: Wings


 
Mar 22, 2021     Ailerons & Flaps - (4 hours) Category: Wings
Progress on first wing: Flap & aileron have full range of motion; Hinges marked and ready to drill.
 
Mar 19, 2021     Ailerons & Flaps - (4 hours)       Category: Wings
Took the Maule out for a few circuits. The wind was a bit squirrelly, but at least I'm (legally) current.

Continued fitting the hinges to the ailerons & flaps.


 
Mar 18, 2021     Ailerons & Flaps - (5 hours)       Category: Wings
Lots of trial and error as I fit & refit the hinges. Whoever said you can't have enough small C-clamps wasn't kidding!


 
Mar 17, 2021     Ailerons & Flaps - (5 hours)       Category: Wings
With wings on a flat table, began the process of aligning ailerons & flaps, fitting of hinges.


 
Mar 16, 2021     Hinges--Flap & Aileron - (2 hours)       Category: Wings
Sanded pieces down to 220 grit; Primed with gray enamel--2 coats.


 
Mar 15, 2021     Hinges--Flap & Aileron - (5 hours) Category: Wings
Using hand file, belt sander, and Dremel tool, took the parts down to smooth enough to prime.
 
Mar 12, 2021     Hinges--Flap & Aileron - (5 hours)       Category: Wings
Continued roughing out the hinge parts.


 
Mar 11, 2021     Hinges--Flap & Aileron - (4 hours) Category: Wings
Using a metal-cutting blade in the jig saw, a hand file, Dremel tool and lots of elbow grease, got half of the hinge blanks to a rough, but approximate shape.
 
Mar 10, 2021     Refabricate hinges - (5 hours) Category: Wings
Took the blanks to my friend's hangar and bend them to 90 degrees in his massive brake. Experienced a bit of tool envy, but it passed.
 
Mar 09, 2021     Hinges - (2 hours)       Category: Wings
On closer inspection, I realized that I had gotten sloppy when I drilled the hinges.. Consequently, it was impossible to get the ailerons and flaps to align properly. Cut blanks for hinge pieces from 1/16" steel. Hacksaw works, but a metal-cutting blade in the jigsaw works much better!


 
Mar 04, 2021     Back to Work - (2 hours) Category: Workshop
It's amazing how many dead flies and wasps can accumulate over the winter! Spent a couple hours cleaning up the hangar and reviewing the build process in my head. Will get back to prepping the ailerons and flaps for covering next week.
 
Feb 01, 2021     EAA Webinars - (3 hours)       Category: Research
Still self-quarantined in the middle of the Pacific Ocean. Took a break from my vacation to check out the Homebuilders Week webinars. Marc Ausman's presentation on avionics was well done—good overview of the basics. I recommend it and his book, Aircraft Wiring Guide.


 
Dec 05, 2020     Break Time - (1 hour)       Category: R&R
Taking a few months in the sunshine. Will get back to work in March


 
Oct 01, 2020     Aileron & Flap - (6 hours)       Category: Wings
Aligned flap & aileron, right wing


 
Sep 30, 2020     Flaps & Ailerons 1 - (3 hours)       Category: Wings
Drilled flap & aileron hinges per plans


 
Sep 29, 2020     Assembly Table 2 Category: Wings
Set up 16-foot table for mounting flaps & ailerons.
 
Sep 28, 2020     Assembly Table - (2 hours)       Category: Wings
Took some time to fly the Maule this morning. Afternoon, drove into town to buy materials for long table.


 
Sep 26, 2020     Rudder - (5 hours) Category: Tail Feathers
Covered rudder using Air Tech materials and techniques.
 
Sep 24, 2020     Elevator 1 - (6 hours)       Category: Tail Feathers
Began process of covering elevator per Air Tech instruction manual.


 
Sep 23, 2020     Horizontal Stabilizer 3       Category: Tail Feathers
Not satisfied with the quality of my work. Stripped fabric, reapplied adhesive, and recovered h.s.


 
Sep 23, 2020     Horizontal Stabilizer 2 - (6 hours) Category: Tail Feathers
Applied fabric to Horizontal Stabilizer. Will shrink and tape when other parts are covered.
 
Sep 21, 2020     Horizontal Stabilizer - (7 hours) Category: Tail Feathers
First venture into fabric covering. Using the Air Tech system, put 2 base coats of adhesive on horizontal stabilizer. Rough cut the fabric.
 
Sep 19, 2020     Avionics - (3 hours) Category: Research
Reviewed procedures for making up wiring harnesses.
 
Sep 18, 2020     Aileron Cove       Category: Wings
Finished aileron coves


 
Sep 17, 2020     Aileron Cove 2 - (4 hours) Category: Wings
Drill, debur, rivet.
 
Sep 15, 2020     Aileron Cove - (4 hours)       Category: Wings
Attached aileron cove using pop rivets--left wing.


 
Sep 12, 2020     Balance Ailerons - (7.5 hours) Category: Wings
Melted, poured, stuffed and cursed lead as I worked on balancing the ailerons. would have finished earlier, but started out by filling the wrong size aluminum tube with lead! all's well that ends correctly, I suppose.
 
Sep 12, 2020     Balance Ailerons - (7.5 hours)       Category: Wings
Melted, poured, stuffed and cursed lead as I worked on balancing the ailerons. would have finished earlier, but started out by filling the wrong size aluminum tube with lead! all's well that ends correctly, I suppose.


 
Sep 11, 2020     Getting Ready to Cover 1 - (1 hour) Category: Fuselage
Pulled elevators off.
 
Sep 10, 2020     Elevator Balance - (2 hours)       Category: Tail Feathers
Melted and poured lead to balance elevators. Will clean up drips, etc.


 
Sep 09, 2020     Avionics - (2 hours) Category: Research
Spent a couple hours probing the mystery of avionics wiring .
 
Sep 05, 2020     Airtech 1       Category: Research
Found some useful videos on Youtube, featuring the owner of the Airtech covering system. found it most informative.


 
Sep 03, 2020     Nutplates - (4 hours) Category: Fuselage
Replaced a dozen or more nutplates with unsatisfactory rivet heads.
 
Sep 03, 2020     Fuel Instrumentation - (2 hours) Category: Research
Spent some time getting acquainted with aux fuel pump and how they get along with the rest of the fuel system.
 
Sep 02, 2020     Reassembly, continued - (2 hours) Category: Fuselage
Reworked front throttle attach. Researched Lyc. OI360.
 
Sep 01, 2020     Reassembly, continued - (6 hours)       Category: Fuselage
Reworked left fuel line. Rebuilt rear throttle attachment. Reworked trim attachment. (With the benefit of time and a bit more experience, i rebuilt the throttle and trim attachments such that I believe both will be more secure.


 
Aug 31, 2020     (Semi-)final details - (5 hours) Category: Bootcowl
Rolled edges of boot cowl sections where they wrap around the nose. Reattached boot cowl.
 
Aug 31, 2020     Beads! - (1 hour) Category: Fuel System
Put bead on ends of fuel lines @ wing root.
 
Aug 29, 2020     Pulley Guards - (6 hours) Category: Controls
Fabricated pulley guards for flap cable assembly
 
Aug 28, 2020     Push to Talk; Control sticks - (5 hours) Category: Controls
Wired PTT, left side. Reinstalled control sticks, replaced temporary hardware.
 
Aug 27, 2020     Push to Talk - (2 hours) Category: Controls
Ran wires & installed PTT in pilot side stick grip
 
Aug 26, 2020     More rivets; Reasembly--fuel tanks - (6 hours) Category: Wings
Added rivets at trailing edge of wings; added padding to fuel tank straps, reinstalled tanks. Began process of replacing hardware store nuts & bolts with AN hardware.
 
Aug 25, 2020     More rivets, a few more do-overs - (4 hours) Category: Wings
Continued filling in missing rivets, remade fuel lines--tank to wing root.
 
Aug 24, 2020     More rivets, a few do-overs - (6 hours) Category: Wings
Worked my way around the wings, pulled & replaced a few unsatisfactory rivets; added some I'd missed the first time through. Remade fuel lines--tank to wing root.
 
Aug 22, 2020     Reassembly, continued - (4 hours) Category: Wings
Reinstalled fuel tank, remade fuel line stubs at tank, reinforced rib @ lightening hole.
 
Aug 21, 2020     Reassembly, continued - (4 hours) Category: Wings
Installed remaining nut plates around fuel bay; disassembled & reassembled flap torque tube assembly
 
Aug 20, 2020     Reassembly, refitting, & Shop Cleanup - (4 hours)       Category: Wings
Cleaned up the hangar, reattached flap mechanism, replaced fairlead removed to provide clearance for riveting; began riveting the second flap bay stiffener


 
Aug 19, 2020     Rivets - (6 hours) Category: Wings
With the help of my able assistant, (nearly) finished riveting the bottom skin on the second wing.
 
Aug 18, 2020     Dynon EFIS.1 - (1 hour) Category: Instrument Panel
Inventoried Dynon components
 
Aug 18, 2020     Wing Skin - (3 hours) Category: Wings
More rivets in bottom wing skin
 
Aug 03, 2020     Rivets - (6 hours) Category: Wings
Attached panel aft of fuel bay. Squeezed the rivets i could get to--will drive the rest when my helper is available.
 
Aug 03, 2020     Rivets - (6 hours) Category: Wings
Attached panel aft of fuel bay. Squeezed the rivets i could get to--will drive the rest when my helper is available.
 
Aug 01, 2020     Reassembly, refitting, & Shop Cleanup - (6 hours) Category: Wings
I spent the day replacing the nut plates that I'd installed earlier (out of sequence), cleaning up the hangar, and refitting a couple of fuel lines that I wasn't satisfied with. Also unwrapped latest shipment from Aircraft Spruce, including part one of my Dynon-based panel.
 
Jul 31, 2020     MORE RIVETS - (5 hours) Category: Wings
We finished up the left wing and got a good start on the right. We found a quarter-size crease in the right lower skin, the result of rolling the skin back a bit carelessly. My A&P will be instructing me on the appropriate repair, involving a shot bag and hammer.
 
Jul 29, 2020     Left Wing Part 5 - (6 hours)       Category: Wings
Finis. Chris and I finished the two-man portion of the left lower wing skin. Chris is getting his bucking chops back and I'm getting more confident on the rivet gun. Next time, I'll reinstall the flap torque tube and pitot tube & prepare the right wing for final riveting of the bottom skin.


 
Jul 29, 2020     Left Wing, Part 3 - (6 hours) Category: Wings
Continued riveting the lower left wing skin. As we near the trailing edge, space gets tighter, more challenging to place the bucking bar squarely on the rivet, but Chris is doing fine, and is conscientious about checking the shop heads with gauge.
 
Jul 28, 2020     Left Wing, Part 4 - (4 hours) Category: Wings
Spent half a day struggling to work single-handedly, bucking rivets near the flap area. Let's just say I'm getting good at drilling out rivets!
 
Jul 25, 2020     Left Wing, Part II - (3 hours) Category: Wings
Installed missing nut plates, left fuel bay.
 
Jul 24, 2020     Left wing - (6 hours)       Category: Wings
Began closing up the left wing--bottom panel. Fortunate to have an experienced, if a bit rusty hand on the bucking bar. We'll learn together.


 
Jul 23, 2020     Riveting Practice - (1 hour)       Category: Wings
Practiced bucking rivets, using scrap aluminum sheet.


 
Jul 23, 2020     Acquired engine - (.5 hour) Category: Engine
Moved engine (0360 Lyc.) into hangar.
 
Jul 02, 2020     Cleanup - (2 hours) Category: Inspection
Swept floor, hauled away 3 months worth of cardboard.
 
Jul 02, 2020     Throttle linkage, Part 2 - (2 hours)       Category: Inspection
Connected front & rear throttles. Adjusted & checked for freedom of movement. Added cotter pins as needed.


 
Jul 01, 2020     Throttle Linkage - (4 hours) Category: Inspection
Threaded 3/16 steel rod to link front & rear throttles. Re-fabricated front throttle lever to accept forked ends.
 
Jun 30, 2020     Cherry-Picker - (5 hours) Category: Inspection
Purchased 2-ton shop hoist @ Harbor Freight. Hauled it to the hangar & put it together. Seems to work fine.
 
Jun 29, 2020     Regroup - (3 hours) Category: Inspection
Inspected wings and fuselage. Compiled pre-cover checklist.
 
Jun 18, 2020     Reassembly - (5 hours) Category: Landing Gear
Reinstalled control torque tube, landing gear. Attached firewall and tunnel w. cloches. Measured length for flex. brake tube-master cylinder to brake caliper.
 
Jun 17, 2020     Brake Lines - (4.5 hours)       Category: Landing Gear
Installed 1/4" hard lines in landing gear. Did a bit of cleanup.


 
Jun 16, 2020     Sight Gauges - (1.5 hours) Category: Fuel System
Tapped Schedule 40 PVC pipe to accept AN fittings. Installed AN822 elbows in each. Will test for leaks tomorrow.
 
Jun 16, 2020     Doors.3 - (3.5 hours)       Category: Fuselage
Finished fitting skin to main door.


 
Jun 15, 2020     Doors.2 - (5 hours)       Category: Fuselage
Put donor plane in the hangar in preparation for enginectomy. Continued fitting and drilling cargo bay door. Started on main door--bottom.


 
Jun 13, 2020     Doors.1 - (3 hours)       Category: Fuselage
Fit & trimmed cargo bay door.


 
Jun 10, 2020     Shock Struts Revisited - (6 hours) Category: Landing Gear
Disasembled and inspected shock struts to determine cause of slow leak. Turned out to be a missing o-ring on the inside of the bronze top cap. Said O-rings were right where I left them, clearly labeled and stowed. Unfortunately, the piston that is located at the center of the strut loosened as I was compressing the spring per the BH Manual, thus precluding my using the "socket method." I spent several hours fabricating and fitting a clamp out of scrap steel and threaded rods to compress the spring. First strut, then, took four and a half hours. The second took half an hour! Note: There's no substitute for quality tools. My hardware store snap ring pliers were simply not up to the task. Borrowed a Snap-On plier from a friend and got the job done quickly!
 
Jun 09, 2020     Do-Overs Are Fun - (3 hours)       Category: Fuselage
In preparation for final assembly, removed firewall. Built a scaffolding to use in raising fuselage. Removed landing gear. Tomorrow, will disassemble and inspect the shock struts, both of which have leaked from day one.


 
Jun 08, 2020     Gotta have brakes - (3 hours) Category: Research
Between visitors, making coffee, and scratching my head, I spent three hours online and in the manuals sorting through the many variations of the brake system layout . After consulting with my IA, I'll likely order. single stainless flexible lines, so as to keep the number of fittings (and potential leaks) to a minimum.
 
Jun 05, 2020     Brake System, Part 1 - (3 hours) Category: Landing Gear
Inventoried and stored hardware order, including AN fittings needed for brake lines and fuel gauge.

Attached brake fluid reservoir on right side of firewall, just to see how it would look.
 
Jun 04, 2020     Nuts and Bolts - (1.5 hours)       Category: Firewall
Replaced AN3 bolts with round 3/16" head machine screws. Added washers and lock nuts.,


 
Jun 04, 2020     Rudder Cables--Forward - (3 hours)       Category: Controls
Made up short cables to connect pilot to co-pilot rudder pedals. Checked AN3 bolt lengths & replaced as needed. Installed cotter pins at required pivot points.


 
Jun 03, 2020     Cleanup - (1 hour) Category: Workshop
It's amazing what you can find if you sweep the floor now and then.
 
Jun 03, 2020     Panel - (2 hours) Category: Research
Researched EFIS/EMS options. Will likely go with Dynon system. Seems to have all the capability I want and need.
 
May 29, 2020     Rudder cables - (6 hours) Category: Controls
Fabricated cables, front to rear rudder pedals. Centered rudder and pedals, cut to fit. Attached with thimbles & Nicopress fittings.
 
May 27, 2020     Conduits & pneumatic tubes - (6 hours) Category: Wings
Bundled the wiring conduit along with the pitot and AOA tubes in the left wing, fed them through the lightening holes and attached them to the ribs from root to tip. Good practice with the rivet gun, as there isn't room for a squeezer where I was working.
 
May 26, 2020     False starts and mis-steps - (4 hours) Category: Wings
Note: as the Bearhawk kits have evolved, so has the assembly sequence, and it appears the various instruction manuals have been rendered somewhat misleading. Take today: earlier kits called for a stiffener to be installed at the rear of the wing prior to final riveting of the skin. Later kits use the same stiffener, but are designed such that the stiffener is sandwiched between the spar flange and the bottom skin. I only realized that after much head-scratching, web-searching, and a quiet but essential Eureka moment, confirmed via a call to Mark Goldberg, the company president. Fortunately, I'd only progressed to the Cleco stage--no rivets to drill out. Moved on to drilling and shaping a hole for the aileron cable to exit the wing at the strut attachment point. Moved on to the left wing, but when I realized I was misplacing tools and talking to myself, decided it was quitting time.
 
May 25, 2020     Control Cables, cotter pins - (4 hours)       Category: Wings
Fabricated aileron cable and installed in left wing
Checked fasteners, aileron and flap actuators
Installed cotter pins as needed


 
May 22, 2020     More details - (4 hours)       Category: Wings
Replaced mis-matched aluminum lines for fuel sight gauges
Installed missing rivet in
Attached elec. conduit
Partial hardware inventory


 
May 21, 2020     AN Fittings - (1.5 hours) Category: Workshop
Sorted & labeled AN fittings for fuel & brake lines.
 
May 21, 2020     Securing conduit - (1.5 hours) Category: Wings
Right wing: Attached brackets @ lightning holes in alternate ribs to secure elec. conduit using 3/16" rivets.
 
May 19, 2020     Trim cable, fuel lines, wing wiring - (4 hours)       Category: Controls
Finished making up trim control cables (1/16" cable, per Barrows drawings). Secured remaining fuel line with Adel clamp. Fabricated& loaded brackets to secure wiring conduit, right wing


 
May 18, 2020     Trim Control - (5 hours) Category: Controls
Having separated the trim tab from the elevator, I filed the tubing and filled the ends with a slurry of microbeads and epoxy. Made up two 1/16 " cables and attached to bell crank.
 
May 15, 2020     Trim Control - (5 hours)       Category: Controls
Attached fairleads at fuselage side, using Adel clamps. Located and attached mount for trim control handle aft and below front throttle quadrant, ala Citabria.


 
May 14, 2020     Trim Control Relocated - (5 hours) Category: Controls
Although the trim control as designed has been proven to be safe and effective, I was not comfortable with reaching overhead and back to adjust trim. Having trained in a Citabria, I wanted to relocate the trim handle to the left side , just aft and below the throttle quadrant. My first idea was to use a Bowden cable in a push-pull setup, but anchoring the housing was a bit too complicated. On further examination, I found that it's a nearly straight run from the left cockpit locations to the attachment at the trim bell crank. Accordingly, using the 1/16" cable specified, I got to work. First task was to replace the hardware store bolts and nuts I'd use in the initial assembly. From there, it has been a slow, but relatively straightforward process of locating fairleads, from the tail to the cockpit.
 
May 13, 2020     Do-Overs continued - (6 hours)       Category: Fuel System
Remade lower fuel line. Began securing lines with adel clamps.


 
May 12, 2020     Do-Overs are OK - (06 hours) Category: Fuel System
Remade fuel lines, installed grommets, tested for leaks.
 
May 11, 2020     Second time's the charm - (4 hours) Category: Fuel System
Remade line, left side from station B to fuel selector. Just didn't like the fit.
 
May 08, 2020     Do-Overs - (6 hours)       Category: Fuel System
Remade unsatisfactory fuel lines, installed grommets @ bulkheads. Tested for leaks using balloon & soapy water.


 
May 07, 2020     Lights - (2 hours)       Category: Research
Still trying to determine if the wingtip light system in the RV series will work in the Bear. I have diagrams and installation docs. but i need one more look at the RV8 three hangars down...


 
May 07, 2020     Shop Cart - (1 hour) Category: Workshop
Little details can make a world of difference. I took a break from bending aluminum to reorient the casters on my shop cart.
 
May 07, 2020     Sight gauges - (2 hours) Category: Fuel System
Fabricated & fit 1/4 tubing for sight gauges
 
May 06, 2020     Details - (4 hours) Category: Fuel System
A clean work space is a sign of a man determined to avoid productive activity. But at my age, it takes too long to find things under the best of conditions, so.. half an hour well-spent. With the wind gusting to 20 knots, it seemed prudent to double -check the tie-downs on the donor airplane: another half hour not working on the Bearhawk... Spent the remainder of the afternoon adjusting, checking, and fitting the fuel lines from the tanks to the wing root.
 
May 05, 2020     Fuel lines - (5 hours)       Category: Wings
Continued fitting fuel lines--main tank ==>wing root. Made cardboard template to get measurements for fuel & fuel gauge lines. Replaced 3/8" vinyl conduit with 1/2" to allow for additional wiring, should need arise.


 
May 05, 2020     Donor Plane - (2 hours)       Category: Engine
Drove to MSO, picked up C-175 with O360 & CS prop to be transplanted into Bearhawk!


 
May 04, 2020     Plumbing - (3 hours) Category: Wings
Fit and secured pitot & AOA lines. Adjusted fuel lines @ wing root
 
May 01, 2020     Fuel Lines: Fuselage.6 - (4 hours)       Category: Wings
Fabricated brackets to support pitot/AOA lines & electric conduit left wing


 
Apr 29, 2020     inspection Covers.2.1 - (6 hours) Category: Wings
 
Apr 28, 2020     FUEl Lines: Fuselage.5 - (2 hours) Category: Fuel System
Decided to replace left fuel line. Station D to fuel selector.
 
Apr 28, 2020     INspection Panels - (3 hours) Category: Wings
Rechecked rivets on inspection ports. Found a few under-squeezed��used hand-squeezer to correct.
 
Apr 27, 2020     Pitot tube mount.4 - (5 hours)       Category: Wings
Installed pitot tube to mast: drilled and tapped p.t. for MS35206-261 machine screws


 
Apr 24, 2020     Pitot tube mount.3 - (02 hours) Category: Fuselage
Installed pitot mast at rear spar.
 
Apr 24, 2020     Fuel Lines: Fuselage.4 - (3 hours) Category: Fuel System
Made up final flare connections, fuel lines to selector.
 
Apr 23, 2020     Fuel lines - (3 hours) Category: Fuel System
Ran line from left side junction to fuel selector. Reviewed manual and Beartracks articles on fuel systems.
 
Apr 23, 2020     Pitot tube mount.2 - (2 hours) Category: Wings
Cleaned and primed pitot mast, installed nut plates on base, prepared wing skin for riveting mount.
 
Apr 22, 2020     Pitot tube mount - (5 hours)       Category: Wings
The Gretz mount is designed for an RV wing. Using the part that came with the mount as a template, fabricated a new backing plate so as to drill holes aligned with the rivet holes in the Bearhawk wing. Drilled out three rivets at attach point ( front spar, outboard of flap/aileron junction) and located hole for pitot mast. Drilled and routed waste using hand-held router and Dremel tool. Will make final attachments when I rivet bottom wing skins closed.


 
Apr 21, 2020     Pitot Tube - (5 hours)       Category: Wings
While I wait for fuel line hardware from Aircraft Spruce, I begin the assembly and installation of the pitot tube. I'm using a Dynon com nation pitot/aoa non heated unit with a Gretz bracket. Seems pretty straightforward, until you get tot he part where you have to cut a hole in the wing skin!


 
Apr 20, 2020     Bending aluminum tubes. - (4.5 hours)       Category: Fuel System
Fuel lines from fuselage sides to selector. Note to self: Should have ordered one more length of 3/8 inch tubing!


 
Apr 18, 2020     Mounting the fuel selector on the mount - (5 hours)       Category: Fuel System
Mark, drill, countersink, deburr, rivet. I finally got everything lined up and in place. Next, to get the lines aligned!


 
Apr 17, 2020     Fuel Selector Mount, Revisited - (4 hours)       Category: Fuel System
Not happy with the fit and finish. Scrapped first try & started over. Like this one better


 
Apr 16, 2020     Fuel Selector Mount - (5 hours)       Category: Fuel System
It took multiple tries, but I pieced together what seems to be a solid mount for the fuel selector.


 
Apr 15, 2020     Fuel Selector - (5.5 hours) Category: Fuel System
Fabricated a mount for the SPRL fuel selector. After reading what Tony Bingelis had to say about side-mounted fuel selected, I chose to go with Barrows's preference: floor-mount, between stations B and C. Mount consists of two pieces of 1/8" aluminum bar tied riveted to half-inch aluminum angle. I will anchor the mount to the welded tabs in the center of the fuselage frame. Gascolator will be mounted directly aft, with a line gently curving back to the firewall.
 
Apr 14, 2020     Fuel Lines: Fuselage.3 - (6 hours)       Category: Fuel System
Before leaving for the hangar, I watched a couple of Youtube videos on tubing & tubing benders. Also downloaded the instruction manual for my tubing bender. Maybe should have done it sooner, but these are strange times. After a bit of head-scratching, and a false start or two (always put the sleeve and nut on the tube before you flare it!), I got the left side (front and rear lines) fitted and connected with a t-fitting (AN824-6D). Felt so good about my work, I did the right side in about a quarter the time it took for the left. Something about following the directions, I guess. Still cogitating on the fuel selector placement. I did discover some vacant real estate on the right side toward the end of the day. We'll see how it looks tomorrow.


 
Apr 14, 2020     Fuel Lines: Fuselage.2 - (4 hours)       Category: Fuel System
With a bit more practice, I took on the task of fabricating the fuel lines from the wing root to the fuel selector. Instead of putting the selector on the floor, I plan to place it on the left side of the fuselage, approximately where it is in the Maule. I'm looking for a familiar placement and the safety of not having to put my head between my knees when I change tanks! We'll see how it goes. I managed to get the left side nearly set in place. I'm still a little shaky with the tubing bender.


 
Apr 11, 2020     Homework - (4 hours) Category: Research
Lacking proper internet in the hangar, I worked at home today, researching fuel systems, electrical planning, and avionics. Fuel seems pretty straightforward, except where the lines have to go around corners. Just remember that, in the absence of other external forces, like a pump, av gas runs downhill. Electrical systems, a bit more complicated, but doable. Avionics? Way too many choices, but for the sake of safety alone, I will figure it out!
 
Apr 10, 2020     Fuel Lines: Fuselage - (4 hours) Category: Fuel System
It was a beautiful day, so I took the Maule out for some much-needed exercise. Airplane did fine. I need a little maintenance.
Spent the afternoon getting acquainted with my tubing bender, with mixed results. (No photos, please).
 
Apr 07, 2020     Dust-proofing - (4 hours) Category: Tools
Closed up table saw & added a dust port.
 
Apr 07, 2020     Lights ? - (2 hours) Category: Research
Researched options for landing/taxi lighting.
 
Apr 06, 2020     Cable Routing - (5 hours)       Category: Wings
Fabricated installed phenolic fairleads to reduced friction in aileron cables


 
Apr 03, 2020     Fuel Tank Bays - (6 hours)       Category: Wings
Drilled, deburred, countersunk many many holes for nut plates. Many, many nut plates.


 
Apr 02, 2020     Fuel lines - (5 hours) Category: Fuel System
Located & drilled holes in inboard ribs, right wing.
 
Apr 02, 2020     Fuel Lines - (5 hours)       Category: Fuel System
Using cardboard templates, a variety of measurements, and my eye, located and drilled holes for the two fuel lines and sight gauge in right wing. Fabricated doublers for critical areas in inboard ribs.


 
Mar 30, 2020     Inspection Plates - (4 hours)       Category: Wings
Finished installing backing plates, & inspection plates in wings


 
Mar 28, 2020     Panel.1 - (2 hours) Category: Instrument Panel
Installed instrument panel per plans and builder manual.
 
Mar 28, 2020     Aileron Cables, Pulley Guards - (3 hours)       Category: Wings
Fabricated & installed fairleads (1/4" phenolic) along aileron cable run. Secured pulleys w. cotter pins; secured cable guards w. zip ties.


 
Mar 27, 2020     Cable routing - (03 hours) Category: Wings
Reinforced lightening holes around cable openings. Fabricated fairleads from phenolic sheet. Centered fairleads on cable openings.
 
Mar 26, 2020     Inspection Plates - (5 hours)       Category: Wings
Installed remaining backing plates & inspection plates in wings. Vacuumed debris from wings. Reinstalled aileron pulleys.


 
Mar 25, 2020     Inspection Plates - (4 hours)       Category: Wings
Primed new inspection plates & backing plates using zinc chromate. Installed backing plates.


 
Mar 25, 2020     Inspection Plates - (03 hours) Category: Wings
Riveted backing plates, right wing using AD426 3-3 rivets.
 
Mar 24, 2020     Inspection Plates - (3 hours)       Category: Wings
Installed backing plates in wings using AD3-3 rivets


 
Mar 23, 2020     inspection Covers - (2 hours) Category: Wings
After a ten-day break for the flu, I resumed work on the inspection covers. Identified un-primed parts & set aside for cleaning and priming. Numbered backing plates & covers for identification. Installed three backing plates using AD3.3 rivets. Two hours was enough. I'm not as tough as I used to be!
 
Mar 12, 2020     Fuel Tank Covers 1 - (4 hours)       Category: Wings
Using edge rolling tool, formed rolled edge around perimeter of covers. Drilled, deburred, & dimpled covers to mate with nut plates in wings.


 
Mar 03, 2020     Inspection Plates - (6 hours)       Category: Wings
Dimpled rivet holes, both wings using pneumatic squeezer. Fabricated backing plate to replace mis-drilled piece.


 
Mar 02, 2020     Rivet squeezer - (2 hours) Category: Tools
Set up and tested pneumatic rivet squeezer.
 
Feb 29, 2020     Inspection Panels - (2.5 hours)       Category: Wings
Installed nutplates on backing plates. Had to replace several inspection plates due to mis-drilling. Used machine screws filed to a point, laid out rivet pattern for inspection plates.


 
Jan 18, 2020     Nicopress Success - (2 hours)       Category: Controls
I seem to have adjusted my eye to the task of accurately lining up the fittings in the tool. I think I can do this!


 
Jan 17, 2020     Cables, etc. - (5 hours) Category: Controls
Received new (expensive) Nicopress tool--the kind with the long handles. Experimenting with various positions and strategies for lining up fittings & getting an accurate squeeze. It shouldn't be this hard!
 
Jan 16, 2020     Let's just call it squeezing - (4 hours) Category: Controls
More practice and an attempt at installing a cable. I began with the shortest run: front rudder pedal to rear. It wasn't very pretty, and practice isn't leading to competence. I'm having trouble lining the Nicopress fittings up such that they squeeze evenly.
 
Jan 16, 2020     Is it sweg or swag? - (4 hours) Category: Controls
With the arrival of my new Nicopress tool, I take a break from the boot cowl and begin to learn the art of cabling. At the same time, I begin to question the wisdom of fabricating my own cables.
 
Jan 15, 2020     Bootcowl Reboot.15 - (5 hours) Category: Bootcowl
More work on the boot cowl. I may be letting the perfect get in the way of the good!
 
Jan 13, 2020     Bootcowl Reboot.14 - (4 hours) Category: Bootcowl
More work on the boot cowl.
 
Jan 11, 2020     Bootcowl Reboot.13 - (3 hours) Category: Bootcowl
More work on the boot cowl.
 
Jan 09, 2020     Bootcowl Reboot.12 - (5 hours) Category: Bootcowl
More work on the boot cowl.
 
Jan 08, 2020     Bootcowl Reboot.11 - (6 hours) Category: Bootcowl
More work on the boot cowl.
 
Jan 07, 2020     Bootcowl Reboot.10 - (5 hours) Category: Bootcowl
 
Jan 06, 2020     Bootcowl Reboot.9 Category: Bootcowl
More work on the boot cowl.
 
Jan 04, 2020     Bootcowl Reboot.8 - (6 hours) Category: Bootcowl
More work on the boot cowl.
 
Jan 03, 2020     Bootcowl Reboot.7 - (6 hours) Category: Bootcowl
More work on the boot cowl.
 
Jan 02, 2020     Bootcowl Reboot.6 - (6 hours) Category: Bootcowl
More work on the boot cowl.
 
Dec 31, 2019     Bootcowl Reboot.5 - (5 hours) Category: Bootcowl
More work on the boot cowl.
 
Dec 30, 2019     Bootcowl Reboot.4 - (5 hours) Category: Bootcowl
Fit bottom sections of boot cowl.
 
Dec 28, 2019     Bootcowl Reboot.3 - (6 hours) Category: Bootcowl
Continued fitting boot cowl
 
Dec 26, 2019     Bootcowl Reboot.2 - (3 hours)       Category: Bootcowl
Continued re-fitting boot cowl.


 
Dec 26, 2019     Throttle Quadrants.2 - (3 hours) Category: Controls
Aligned and attached rear throttle to fuselage tabs using AN hardwared.
 
Dec 21, 2019     Bootcowl Reboot Part 1 - (6 hours) Category: Bootcowl
First try wasn't a great success. Beginning with posterboard patterns, I carefully cut new pieces for the bootcowl, starting at the top. I included an access panel at the instrument panel to facilitate maiintenance down the line.
 
Dec 17, 2019     Throttle Quadrant - (06 hours) Category: Landing Gear
Using aluminum square tubing, fabricated mount for 3-LEVER CT83F QUADRANT and 1 LEVER QUADRANT (Front: ACS 05-00703 and Rear ACS 05-04531) Drilled, deburred, & Clecoed @ preinstalled tabs, left fuselage.
 
Sep 04, 2019     More cables - (6 hours) Category: Controls
More work on the rudder cables. Lots of frustration getting a good, even swage on the Nicopress fittings. Many false starts. My first attempt at connecting the pedals to the rudder is not particularly impressive. There's very little room for error, and I'm not quite getting the feel for aligning the three required squeezes.
 
Sep 03, 2019     Cables, etc. - (6 hours) Category: Controls
More practice with the Swage It tool. First attempt at fabricating rudder cables. I started with the shortest ones, in an effort to conserve cable: pilot to co-pilot linkage. Installed rudder springs from the local hardware store. Glad they're not expensive, because the first ones seem to be too long!
 
Sep 02, 2019     Pulleys, Pulley Guards, & Cables - (6 hours) Category: Controls
Located pulleys for rudder, aileron, flaps & installed in respective locations. Fabricated guards from .032 aluminum. Spent an hour or two getting acquainted with my Swage It tool. This could take some practice.
 
Aug 30, 2019     Firewall - (2 hours)       Category: Firewall
Fitted and attached firewall and engine mount per plans and Beartracks. Temp. hardware.


 
Aug 29, 2019     Nuts & Bolts - (4 hours) Category: Research
Aircraft Spruce Order; nuts, bolts, etc
 
Aug 28, 2019     Shop Carts - (4 hours)       Category: Research
Built 2 rolling shop carts--dual purpose: tool management & wing transport.


 
Aug 28, 2019     Gear Legs - (2 hours)       Category: Landing Gear
Attached gear legs.


 
Aug 27, 2019     Trim Tabs - (4 hours) Category: Empennage
Cut trim tabs free from elevator. Reattached using standard hardware. Attached trim/pushrod assembly. Aligned and drilled actuating arms.
 
Aug 26, 2019     Cleanup - (2 hours) Category: Workshop
Stowed tools & materials; swept hangar & hauled accumulated trash.
 
Aug 26, 2019     Aluminum formers.2 - (4 hours)       Category: Fuselage
Finished installing formers as above.


 
Aug 24, 2019     Aluminum formers.1 - (4 hours)       Category: Fuselage
Fit aluminum formers to sides, bottom of fuselage. Attached using pulled rivets.


 
Aug 23, 2019     Floor boards - (6 hours)       Category: Fuselage
Fit floor boards from firewall aft. Drilled through tabs to accept 3/16 in. screws & tinnermans.


 
Aug 22, 2019     Tail Feathers Part One - (6 hours)       Category: Empennage
Assembled and mounted horizontal stabilizer, elevator and rudder. Attached horizontal stabilizer struts. Connected elevator pushrod. Note all assemblies attached with standard hardware--to be replaced at final assembly with AN hardware


 
Aug 21, 2019     Control Stick - (5 hours)       Category: Controls
Assembled and installed control stick per plans and assembly manual using hardware store bolts (to be replaced on final assembly with AN hardware).


 
Aug 20, 2019     Rudder Pedals, Flap Handle - (5 hours) Category: Controls
Assembled and installed rudder pedals, front & rear per plans, Bearhawk Assembly Manual. Assembled and installed flap handle mechanism per plans, BAM.
 
Aug 19, 2019     Back to (the real) work) - (8 hours) Category: Workshop
Moved AC back into hangar; set up shop. Built shelves, assembled work tables, hung lights
 
Aug 16, 2019     Paint, second coat - (5 hours) Category: Workshop
Moved everything to the other side of hangar, painting continued
 
Aug 15, 2019     Watching Paint, cont'd - (8 hours) Category: Workshop
Floor prep. 1st coat of epoxy-based paint
 
Aug 14, 2019     Watching paint Dry cont'd - (8 hours) Category: Workshop
Stripped old paint using floor machine
 
Aug 13, 2019     Watching Paint Dry - (4 hours)       Category: Workshop
My two trusty assistants stripped and painted the hangar floor this week. (I may. have gone fishing)


 
Aug 12, 2019     Hangar Rehab - (4 hours) Category: Workshop
In preparation for floor refinishing, resident aircraft (Maule MX7-160; Luscombe 8F) relocated to ramp tie-down; all tools, benches, etc, moved to side of hangar
 
Aug 12, 2019     You Gotta Have Wheels to Fly - (3 hours) Category: Research
��esearched tires & wheels on line
��rdered tailwheel from Bearhawk Tailwheels LLC
��rdered tires & tubes from Aircraft Spruce

 
Aug 10, 2019     Shock Struts - (6 hours)       Category: Landing Gear
Assembled shock struts per Builder's Assistance Manual (BAM) and drawing # 28.
��eburred and polished inside of strut tube with emery cloth
��ubricated O-rings
��nstalled spring to shaft using bolt-socket method
As noted in BAM, installation of snap rings was a challenge


 
Aug 09, 2019     Christmas in August - (4 hours)       Category: Inspection
Opened, inspected, inventoried parts & pieces packed in fuselage.


 
Dec 31, 1969     Re-Do.2 - (4 hours) Category: Fuel System
Completed re-do on fuel lines. Aligned bends at wings to meet lines coming out of fuel tanks.
 
Dec 31, 1969     FLAP HINGE - (2 hours) Category: Wings
Fabricate Flap Hinge
2
 


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