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

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.


 
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!)
 
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     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


 
Aug 30, 2021     Finish Tape - (4.5 hours)       Category: Wings
Applied finish tape, both 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.
 
May 29, 2021     Hanging Wings.1 - (4 hours)       Category: Wings
With the assistance of three neighbors, got the wings mounted for the first time.


 
Apr 29, 2021     Gussets - (5 hours)       Category: Wings
Attached gussets to ailerons & flaps; ordered parts


 
Apr 24, 2021     Gussets - (4 hours) Category: Wings
Attached gussets and trailing edges on ailerons & flaps
 
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 16, 2021     Ailerons & Flaps - (5 hours) Category: Wings
Drilled hinge plates & installed nut plates on spars.
 
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 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!


 
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 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.


 
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     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.


 
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     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 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 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     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 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 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.


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


 
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.


 
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.


 
Dec 31, 1969     FLAP HINGE - (2 hours) Category: Wings
Fabricate Flap Hinge
2
 


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