Jan 16, 2022     Re-Start - (1 hour) Category: Research

After a hiatus fromt he project due to needed projects in the house and yard it is time to get serious about this build.
Some time was speent remembering where we were in the project and what our next steps need to be.
The wing rib forms need to be completed. Only a few masters were built at this point. Howeve, the first step will be the need to build the router table. It is needed to cut the masters to all the smae size and then will also be used to trim the rib blanks.

  Apr 26, 2021     Engineering Changes - (0.1 hour)       Category: Changes

Flap Hinge Drafting error.
Source: Bob Barrows

  Feb 18, 2021     Aluminum Shipment Received - (.3 hour)       Category: Wings

Received first shipment of aluminum for wing ribs.
Wicks Invoice # 5752280
5 4' x 12' Alclad 2024T3 .025
1 4' x 12' Alclad 2024T3 .032

  Feb 10, 2021     Wing Rib Template & Forms - (3.5 hours)       Category: Wings

We were able to obtain a 4' x 8' sheet of damaged aluminum (about .025) from Angela's work at a reasonable price. This to be used to make the master Wing Rib Template as well as other test pieces, rivet practice etc.

The full size Wind Rib Mylar drawing #4 was taped to this large sheet and a rough cut piece made. The Mylar template was then glued to the aluminum using 3M 77 spray adhesive and allowed to dry overnight. Angela and Rocky both rough cut out the template using electric sheet metal sheers. Left and straight tin snips were then used to cut the form within 1/8 inch of the outline. Then the template was taken to a bench grinder to get as close as possible to the line. One small “oops” occurred when the grinder drew it in too far and removed too much. Not an issue as it was not a lot and can be compensated for when the template is used.

Final sizing of the aluminum Master Wing Rib Template was done by hand filing. Manuals and the Bearhawk Forum was consulted with regards to the question should it be trimmed to the outside Vs inside the line? While we do not want to over think the process we felt it was good to get some input. The general consensus is file to the middle of the line even though either way may not be that critical. The reason being this is a template for “our” airplane and all the part will be made the same and the most critical dimension is Main spar to Rear Spar dimension of 32 inches must be maintained.

Per the above discussion the Template was fine formed to roughly the middle of the line. Jig holes, Lightening Hole locations were all center punched and drilled out to 3/16 inch.

We consider this our first minor milestone, the competition of the Wing Rib Master Template.

The Template was then placed on a 12” x 6' piece of 1” thick MDF. The outline, jig & lightening hole locations, Chord line, Spar Center Lines were all transferred to the MDF. A sabre saw was used to rough cut out the MDF.

(Editor's Note: Unable to rearrange the order of photos below)

  Feb 04, 2021     Sheet Metal Brake - (3.0 hours) Category: Tools

We obtained the 30 inch sheet metal brake from Harbor Freight. From what was researched it looks like this will be adequate for most the smaller parts. The main issue with this brake is that it is not configured well for doing a large quantity of parts repetitively. In our case, doing many rib stiffeners.

Rocky is making modifications to the brake. Creating a spring loaded hold down for the nose radius bar. In addition, obtained some 16 Ga. Steel to make a nose radius bar shim that will allow for 0.125 inch bends on the stiffeners. This as a result of some bend testing that was done to also verify my math.

Pictures of completed project to follow when it is done.

We are anxious and soon ready to start cutting REAL aircraft parts.

  Feb 04, 2021     Plans review - Focus on rib parts. - (4.0 hours) Category: Plans Review

Rocky went through the drawings and created a spreadsheet materials list that will be required.

We have a sheet of 6061-T6 x .125 that I purchased as part of my earlier MiniMax project. This looks like it may be close to enough required for parts to be make from it. I also have a few of the Spar parts made from 6061-T6 x .126 that was made for the original 4 place Bearhawk. These parts also do not match up with the Patrol requirements but a few of them can be used for smaller parts..

Things to research & To-Do's:
1. How are the lengths of 4130 Tubing determined in order to purchase correct amounts?
2. If I use the original 6061-T6 material anywhere, Do I still have documentation of purchase?
3. Get the invoice for the sheet of 6061-T6 I purchased for the MiniMax.
4. What material is Angela getting for the template? If laminate, do we need to worry about it being prone to breaking? That might be the advantage of using aluminum sheet. Update 02/04/2021 - Picking this up today.
5. We need to get some markers.
6. Count how many nose rib blanks I had. Not critical.
7. Study and document how to do metal bending so we can have the process down pat. COMPLETED

Rocky reviewed Drawing #3 to determine non-dimensioned areas. Include the length of the stiffeners that will be required and the diameter of the lightening holes. They drawing is 1/2 scale. And per Bob, “Scale all no-dimensions.”

Sizes and number of .025” x 1/2" x 1/2" stiffeners for wing ribs:
(30 ) 6-1/2”
(24 ) 8-1/4”
(24) 7-1/4”
(24) 8-3/4”

  Feb 03, 2021     Test Rivet Gun - (.5 hour) Category: Tools

The ACAT 4x rivet gun we purchased on eBay did not have the attachments.. These were ordered and received. Assembled and tested the gun. Having never used one before other than was was given to us at the Oshkosh workshop in 2019, we needed to learn how the trigger and adjustment worked on it. Also verified (from a builder hint) how air pressure can benefit proper force etc. Both of us familiarized ourselves with this.

  Feb 03, 2021     Plans protection - (.3 hour)       Category: Admin

We received the portfolio presentation book for the plans and placed them into it.

  Jan 29, 2021     Inital Plans Familiarization - (3.0 hours) Category: Plans Review

Reviewed the plans, handbook and other material. 0.5 Hrs.

Opened up the full size rib plan DWG # 7 (Mylar). Verified the 1 inch MDF piece we have will be large enough. We will need one more for the Backing Form. We should have enough pieces in stock for the smaller Form Blocks but yet need to verify. 0.25 Hrs.

We have about __ Nose Rib blanks I made a few years back for the Original 4 Place Bearhawk. Per Bob Barrows, the new airfoil will not allow me to use these. However I compared these nose rib blanks against the Mylar template and indeed a bit too small. This 2024-T3 material can be used to make smaller parts like the Stiffeners. .25 Hrs.

Angela has the advantage of obtaining various materials through work scrap and we are getting some material to make a permanent template from the Mylar plan. Many people transfer the full size layouts in various ways. Bob's Manual suggests gluing the Mylar to aluminum to make a template and then transform this to the MDF forms. We are not concerned about keeping the Mylar template in its originality so we plan to go with this approach but looking to make a template from ___ that Angela can get from the shop. I have been told a replacement form can be purchased from Bob if needed.

Went through the drawings and created a spreadsheet materials list that will be required.
2.0 Hrs.

  Jan 29, 2021     The Plans Have Arrived - (1.0 hour)       Category: Admin

Entries

We are excited. The plans have arrived. We did the obvious Happy Dance and reviewed the material. Our Serial Number is # 443. Thank you Bob & Diane Barrows of R & B Aircraft.

Now we can review and start to determine what and how much raw material we will need to purchase.

  Jan 29, 2021     Received Tools & Accessories - (0.5 hour)       Category: Tools

Received the tools and accessories ordered from Yardstore today. We should no have most of what we need to get started.Obviosly we will add more as it goes along. Included in this shipment are the parts for the rivet gun purchased on eBay.

  Jan 28, 2021     Orginazation of parts - (2.0 hours)       Category: Workshop

While waiting for plans and after receiving first batch of rivets. I deceided to create a convienient way to store and access them.

  Jan 27, 2021     Tools & Accesories Procurment - (2 hours) Category: Tools

Week of 1/29/21

Ordered more tools and tool accessories consisting of the following:
• 1 10502 Rivet Set 1/8” Straight 3 1/2
• 1 10501 Rivet Set 3/32” Straight 3 1/2
• 1 10003 Rivet Set 5/32" Straight 3 1/2'
• 1 10004 Rivet Set 3/16" Straight 3 1/2'
• 1 Rivet Retainer Spring
• 1 15000 Bucking Bar (670)
• 1 7204 BOELUBE 4OZ BLOC1K WHITE 70200-14 (to be used to lube router bits).
• 1 13161 Rivet Fan Spacing Tool (10 Hole)
• 1 14031 Dogleg Deburr Tool with Bit
• 4 11089 Side Grip Clecos 3/4" x 1/2"
• 4 11092 Side-Grip Clecos Clamps 3/4" x 1"
• 10 11013 K Series Spring Cleco 5/32" (0-1/4")
• 10 11014 K Series Spring Cleco 3/16" (0-1/4")

Created labels for rivet storage. Labeled rivets stored with lot numbers tied to invoices for future references as they will be used in building. Future documentation will include this information in the construction log as we use these parts. This may be a bit anal but I guess this comes from days working with quality control departments.

Picked up air drill that my dad use to have in his auto body days. Needed to swap out a different adaptor for my compressor. Tested perfect.
Received the air rivet gun I purchased off eBay. This also needs a different air adaptor to test and use.

  Jan 25, 2021     Raw Material Received - (.5 hour)       Category: Workshop

Received the rivets from Wicks Aircraft.
MS20470AD3-2, 1/8lb, LotNo. 7258/A
MS20470AD3-3, 1/8lb, Lot No. S190528009M
MS20470AD3-4, 1/8lb, Lot No. S120313007L
MS204704-5.5, 1/8lb, Lot No. R-830-298
MS20470AD4-6 1/8lb, Lot No. R-830-302-E

We will be using these rivets for riveiting practice as need for both Angela & I to become efficent.

  Jan 23, 2021     Weekly Update - Mid January - (4 hours)       Category: Admin

This past week we received acknowledgment from Bob & Diane Barrows that they received our 2nd check for plans and that they are now shipped out to us. It will not be long now before we can really get started.

In the meantime we ordered some AN470AD3-2, AN370AD3-3, AN370AD3-4, AN4704-5.5, AN470AD4-6 rivets, #40 & #30 clecos and cleco pliers, Sized drill bits. While in small quantity right now we will use these to practice our riveting skills at the same time we will start working on rib blanks, etc.

Also purchased a 30 inch metal bending brake from Harbor Freight. From what I can tell this should work fine for most the bends. Still need to find a location for the spars when it comes time. Unpacked the brake and indeed it might need a little modification to assist with material setup when using.

  Jan 18, 2021     While waiting for plans Category: Admin

No hours entry here. Angela and I are still waiting for our plans. There seems to be a mail delivery issue as the check was mailed to Bob back on December 28th.
In the mean time we are configuring the basement workshop area with what we will need for the build.

  Jan 06, 2021     Order - (0.2 hour) Category: Tools

Ordered laminate router bits to be used in final sizing of rib parts.

  Jan 06, 2021     Parts & Tools Needed Research - (3.5 hours) Category: Research

Researched what rivets are used on the Patrol from a BOM sheet. Used this to also recognize what drill bit sizes we will need. Spent time making up a tools needed list and researched prices and sources. Angela ordered a sheet of 1" MDF from work. Reviewed with Angela how rivets part numbers work, and the basic tools and processes. both of use did the workshop at Airventure in 2019 so it was a bit of a review.

  Jan 04, 2021     Shop Prep - (3 hours) Category: Workshop

Still waiting for plans so we are working on setting up the workshop. Angela and Rocky cleaned out the area so it will be dedicated to the project. 2x4's cut for workbenches and assembly started on those workbenches.
While these hours do not refelct airplane build time, it is still time towards the goal of doing something on the project every day. The amount of work I (Rocky) can do at this time is a bit limited due to a current back pain issue. Still moving forward.

  Jan 03, 2021     Building shop benches - (1.5 hours) Category: Research

I already have a large 4' x 16' workbench from a previous project but this will be used later. Decided to make a smaller one (3' x 6') to work on smaller parts for now. Also making a small tool staorage bench dedicated to the airplane build. Need to do something until the plans get here.....:-)

  Jan 01, 2021     Prepwork - (1 hour) Category: Workshop

Started bringing the tools from previous workshop to our new home's workshop area. Nothing exciting but small tasks that need to be done while waiting for plans. The goaol beoing spend SOME time everyday....

  Dec 31, 2020     Purchase Wings Builder Manual Category: Photos, Misc

Purchased the downlaodable PDF of the Wings Builder Manual. Backup of the PDF sent to Angela's email.

  Dec 28, 2020     Plans Ordered Category: Research

Ordered plans for the Bearhawk Patrol from R & B Aircraft & 2020 issues of Beartracks.