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Project: Barnhawk -
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Builder Name:	David Pearson -

Project:	Bearhawk - 4 Place - VIEW REPORTS
Total Hours:	1497.1
Total Flight Time:
Start/Last Date:	Aug 22, 2021 - No Finish Date

Friendly URL:	https://eaabuilderslog.org?s=Barnhawk

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May 07, 2024 Flap and Aileron Hinges - (4 hours) Category: Wings

Drilled 1/8" pilot holes in all hinge plates for flap/aileron spar attach bolts.

May 05, 2024 Right Wing Control Surfaces - (5 hours)

Category: Wings

Finished drilling out pop rivets and removing gussets from aileron. Match-drilled top skin to aileron bay cove ribs. Clecoed top flap bay skin stiffener in place. Lower skin flap bay section intrudes into aileron bay about 1/4", interfering with aileron placement: Top skin trailing edge "tongue" of bay measures 67-3/8" to tip rib, bottom skin recessed section measures 67-3/16". Marked lower skin and stiffener for trimming.

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May 04, 2024 Right wing trailing edge and control surfaces - (4 hours)

Category: Wings

Finished aligning, match-drilling, and deburring root ribs.
Removed gussets from flap, goofed up one 1/8" hole. Ordered NAS1097AD-5 "oops" rivets, various lengths, for repair.
Started removing gussets from aileron.

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May 03, 2024 Right wing trailing edge - (1 hour)

Category: Wings

Right wing trailing edge ribs: trimmed 1/8” from #1 to compensate for extra rear spar thickness. Match drilled rib 1, 2 holes only. Using thread to align ribs 1 and 2 with tip rib.

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May 02, 2024 Right Wing Control Surfaces - (1 hour)

Category: Wings

Received and inventoried parts from ACS.
Confirmed root TE Rib (#1) needs to be trimmed 1/8" to compensate for 1/8" plate at root end of rear spar. Marked rib accordingly.

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May 01, 2024 Right wing control surfaces - (1 hour)

Category: Wings

Right wing: unwrapped aileron and match marked gussets to spars. Made Mdf blocks to help mock up root rib alignment.

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Apr 29, 2024 Right flap - (1 hour)

Category: Wings

Unwrapped right flap and marked parts to be removed during installation process. That'll help me get them back in the right spots.

Ordered fasteners required for flap and aileron installation.

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Apr 28, 2024 Right Wing Control Surfaces - (4 hours)

Category: Wings

Used laser level to level wing table.
Confirmed that wooden template matches wing profile drawing #7.
Checked drawing #7, found that trailing edge of control surfaces is 0.5" below the the bottom surface of the wing (formed by extending a horizontal line between the bottom of the main spar and rear spar). Set up shims on table accordingly, to yield the appropriate convex surface to the bottom surface of the wing+control surfaces.
Clecoed tip TE rib into place (factory drilled) and confirmed that it matches the template.
Clamped root TE ribs into place, discovered that rib #1 needs to be trimmed 0.125" to compensate for material thickness difference in rear spar at that location.

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Apr 27, 2024 Right Wing fuel tank grounding - (2 hours)

Category: Wings

Installed ground leads for main and aux tanks in right wing. Used AN742-D16 clamps at tank bungs, bonding brush to remove primer at contact points on ribs. Applied GB Ox-Gard to all surfaces. Washer used at contact points with aluminum rib is AN960JD10L - Washer - Flat - #10 - ID: .203, OD: .438, Thickness: .032 -Aluminum, Chemical Conversion Coating, IAW AC 43.3-1B.

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Apr 26, 2024 Wing grounding, Flap and Aileron mounting - (4 hours)

Category: Wings

Inventoried parts for Flap and Aileron mounting, figured out what I need to order.
Installed grounding studs (MS35207-266) in root ribs of both wings, IAW AC 43.13-1B TABLE 11-14. Newly purchased bonding brush from Yardstore (3/16" pilot, 1/2" OD) works great for removing primer. Washer used at contact points with aluminum rib is AN960JD10L - Washer - Flat - #10 - ID: .203, OD: .438, Thickness: .032 -Aluminum, Chemical Conversion Coating, IAW AC 43.3-1B.
Applied GB Ox-Gard to all surfaces.
Shifted rotisserie and table around in shop to get access to right wing on table.
Started crossing off last few checklist items on right wing:
Replaced snap bushings in Aux Tank bay with grommets.
Added solder to Packard connector crimp @ transfer pump.

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Apr 25, 2024 Flap and Aileron mounting - (2 hours) Category: Wings

Research drawings and build instructions for Flap and Aileron mounting. Completed BOM of all fasteners needed.

Apr 24, 2024 Flap and Aileron mounting - (2 hours) Category: Wings

Researched build manuals (scratch build, old kit, online at bearhawk.tips), plans, and forum postings about flap and aileron mounting.

Apr 23, 2024 Left wing aux tank alignment and binding studs - (2 hours)

Category: Wings

Left wing: got aux tank top strap bent to align tank with opening better. Ordered MS35207-266 screws to use as bonding studs at wing roots.

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Apr 22, 2024 Left aux tank alignment - (2 hours)

Category: Wings

Left aux tank alignment: tank keeps wanting to shift aft when straps are tightened. Using blocks to hold it forward while tightening straps seems to help a bit. Trying to avoid opening up the hole too much.

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Apr 20, 2024 Left aux tank ground - (2 hours)

Category: Wings

Left aux tank ground: pulled tank, attached ground wire with in line quick connect to tank bung and mount point on rib, replaced tank.

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Apr 18, 2024 Fuel tank grounding - (1 hour)

Category: Wings

For ground connection to fuel tanks, decided to use AN742-D16 clamp on the outlet bung of each tank (with No-Ox applied to all mating surfaces). Got the left main tank done and wired to an existing bolt on rib #2.

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Apr 16, 2024 Left wing - (4 hours)

Category: Wings

Left wing: primed and reinstalled aileron bellcrank. Test fit shackles, all good now. Marked and drilled pilot hole for front aileron cable. Trial made a clamp to attach ground lead to fuel tank bungs. Material .025” 2024-T3, 1/2” wide, 4.25 long.

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Apr 14, 2024 Left Wing Internals - (4 hours)

Category: Wings

Laced root end of wiring harness and temporarily bagged harness end to avoid contamination. Re-installed inboard aileron cable pulley. Replaced surveyor's line used to simulate aileron cable to visualize routing near pitot tube. Used chainsaw file to remove excess weld on aileron bellcrank that was interfering with AN115-21 shackle.

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Apr 13, 2024 Left wing wiring and plumbing - (4 hours)

Category: Wings

Left wing: routed and secured pitot wiring and plumbing using lacing cord. Terminated root end of all wiring. Molex connector for pitot heat connection looks good, used hst for strain relief.

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Apr 12, 2024 Left wing wiring - (2 hours)

Category: Wings

Left wing wiring: continued positioning and wire management. Used lacing twine for bundling. Initial fit of pitot heat wiring. Flame tested automotive wire to be used for pitot heat, confirmed self extinguishing.

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Apr 09, 2024 Left wing wiring - (2 hours)

Category: Wings

Left wing wiring: started routing wires and installing wire retainers.

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Apr 08, 2024 Left wing electrical conduit - (1 hour)

Category: Wings

Left wing: riveted electrical conduit into place. Used CCP-43 rivets, with AN960-6L washer under rivet head and AN960-4 washer at shop end.

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Apr 07, 2024 Left wing internals - (3 hours)

Category: Wings

Fabricated shim to close the gap between joggled flange of pitot mast and top surface of main spar cap. Material used: .025 2024-T3. Primed shim and riveted into place with AN426AD-3 rivets.
Tried multiple techniques to crimp the conductor crimp of the Packard 56 terminal for aux fuel pump without success. Best result passed pull test but had slight conductor movement. Crimped insulation strain relief, and then filled the conductor crimp with solder successfully. Will check the corresponding connector on the right wing, and may give it the same treatment.

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Apr 06, 2024 Pitot mast mounting - (2 hours)

Category: Wings

Left wing: riveted pitot mast doubler in place.

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Apr 05, 2024 Left wing wiring - (4 hours)

Category: Wings

Purchased and twisted red/black 12AWG primary wire for pitot heat power. Terminated wingtip lighting cables w/ Deutsch DTM connectors. Updated left wing wiring diagram by adding:
- Magnetometer and harness
- Pitot plumbing
- Pitot heat controller and wiring

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N716GR Electrical System-Left Wing.drawio.pdf

Apr 04, 2024 Pitot heat planning - (3 hours)

Category: Wings

Looked at electrical requirements for Pitot Heat. Garmin is worst-case, requiring 12AWG wire, 20A breaker. Dynon specifies a 10A breaker. Selected and purchased Molex connectors from DigiKey suitable for this load. Primary wire (power and ground) will come from AutoZone.
Either Dynon or Garmin controller will fit on the inside surface of inspection plate 2L - see photos.

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Apr 02, 2024 Left wing: pitot mast and wiring - (2 hours)

Category: Wings

Left wing: dimpled screw holes for pitot mast using dimple block and rivet gun after 4 practice shots on a piece of scrap. Started work on wiring diagram. Need to add pitot plumbing and wiring, and magnetometer wiring.

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Apr 01, 2024 Left wing magnetometer mount - (1 hour)

Category: Wings

Left wing magnetometer mount: drilled out the two mistakenly placed flush head rivets. Installed four AD32ABS round head rivets. Installation complete!

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Mar 31, 2024 Left wing magnetometer mount - (1 hour)

Category: Wings

Left wing magnetometer shelf: set outboard flush rivets. Set two PAAK302 blind rivets on inboard side but realized that they are flush head not round head as required. Ordered correct rivets from Olander.

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Mar 30, 2024 Left wing magnetometer mount - (1 hour)

Category: Wings

Left wing magnetometer mount: primed mounting bracket.

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Mar 29, 2024 Left wing fuel lines and wiring conduit - (3 hours)

Category: Wings

Left wing: remade aft main tank outlet line. Drilled and deburred holes for wiring conduit hangers.

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Mar 27, 2024 Left wing magnetometer bracket - (1 hour)

Category: Wings

Left wing magnetometer mount: finished drilling and deburring.

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Mar 26, 2024 Left wing magnetometer moint - (5 hours)

Category: Wings

Left wing: made form blocks and finished forming magnetometer tray. Drilled tray to wing bottom skin and rib. Deburred hall holes. Dimpled holes in bottom skin and corresponding holes in tray. Started drilling tray to accommodate both Garmin and Dynon magnetometers.

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Mar 25, 2024 Left wing: magnetometer mount - (2 hours)

Category: Wings

Left wing magnetometer mount: spent a long time figuring out bend allowances and set backs and sight lines.

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Mar 24, 2024 Left wing plumbing and magnetometer - (4 hours)

Category: Wings

Left wing internals: good results from overnight pressure test of fuel system. Started fabricating magnetometer shelf from 2024-T3 .032” sheet. Sketches in photos.

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Mar 23, 2024 Left wing plumbing, seaming pliers - (3 hours)

Category: Wings

Left wing plumbing: pressure test failed. Soapy water located leaks between 9 mil nitrile gloves and fuel filler necks. Replaced gloves with thin ones and restarted test. Ambient temp 64F. Looked good at 2130, will check again in the morning.
Also modified 3” and 6” seaming pliers, ground and polished one jaw with 1/8” bend radius.

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Mar 22, 2024 Left wing plumbing - (1 hour)

Category: Wings

Left wing plumbing: pressure test of both tanks and all lines. Used Harbor freight 9 mil gloves on filler necks. Lost all pressure by morning.

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Mar 21, 2024 Left wing plumbing - (1 hour)

Category: Wings

Left wing internals: received pitot static plumbing kit from Steinair. Reinstalled aux tank. Started preparing for fuel system pressure test.

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Mar 20, 2024 Fuel system pressure testing research Category: Wings

Link to EAA video on pressure testing fuel tanks: https://www.eaa.org/videos/5308253018001

Mar 19, 2024 Left main tank plumbing - (2 hours)

Category: Wings

Left wing: increased clearance for main tank drains in rib 2. Installed drain lines.

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Mar 18, 2024 Left main tank plumbing - (1 hour)

Category: Wings

Left main tank plumbing: tank shifted aft about 3/16” when straps were tightened. This threw off the alignment of ports to holes in rib 2. Working on a solution.

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Mar 17, 2024 Left main tank plumbing - (4 hours)

Category: Wings

Left main tank plumbing: finished up sight gauge lines. Installed strainers and fittings for outlet lines. Discovered tank seems to have shifted aft when when removed and installed after I marked the tank bung locations.

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Mar 16, 2024 Left wing plumbing - (3 hours)

Category: Wings

Left wing plumbing: ran aux tank feed line between ribs 1 and 2. Needed to sacrifice a drill bit to drill the hole for the Adel clamp to support the line.

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Mar 15, 2024 Left wing internals - (4 hours)

Category: Wings

Left wing internals: mocked up mounting bracket for magnetometer. Designed for either Garmin GMU 11 or Dynon SV-MAG-236. Reinstalled main tank and fabricated top sight glass line.

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Mar 12, 2024 Left aux tank plumbing - (3 hours)

Category: Wings

Left aux tank plumbing: fabricated and installed line from transfer pump to bulkhead elbow fitting at rib #2.

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Mar 11, 2024 Left wing wiring - (1 hour)

Category: Wings

Left wing wiring: drilled 1” pass through holes aft of aux tank and installed grommets.

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Mar 10, 2024 Left wing plumbing and wiring - (3 hours)

Category: Wings

Left wing: finished installing aux tank vent and associated doubler. Marked hole locations for wiring pass throughs in aux tank bay.

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Mar 09, 2024 Left main tank plumbing - (3 hours)

Category: Wings

Left main tank plumbing: drilled all holes for feed and sight glass lines in ribs 1 and 2. Relocated serial number plate which interfered with front feed line location.

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Mar 08, 2024 Left main tank plumbing - (2 hours)

Category: Wings

Left main tank plumbing: marked and started drilling holes in rib #2.

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Mar 06, 2024 Left wing plumbing - (1 hour)

Category: Wings

Left wing: removed main and aux tanks. Started marking #2 rib for main tank plumbing pass thrus. Photos of right wing attached here. Noted bottom sight glass pass thru is significantly offset from rib holes, to avoid joggle around lightening hole in #2 rib.

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Mar 05, 2024 Left wing fuel lines - (3 hours)

Category: Wings

Left wing fuel lines: drilled holes for line from aux pump to main tank. Measured main tank fitting locations.

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Mar 03, 2024 Left aux tank vent - (2 hours)

Category: Wings

Left aux tank vent: fabricated shim from .025 2024-T3 to provide flat surface for elbow fitting.

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Feb 29, 2024 Left aux tank vent - (1 hour)

Category: Wings

Left aux tank vent: finished forming and trimming underwing vent tube.

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Feb 28, 2024 Left aux tank vent - (1 hour)

Category: Wings

Left aux tank vent: installed 10-32 nut plate to support Adel clamp.

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Feb 26, 2024 Left aux tank vent - (1 hour)

Category: Wings

Left aux tank vent: measured location of 7/16” hole in wing skin for underwing vent on right wing. Photo is of hole location in right wing. It's 3/8” aft of spar cap, 9/16” outboard of rib flange. Will duplicate this on left wing.

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Feb 25, 2024 Left wing: flap arms and aux pump grounding. - (3 hours)

Category: Wings

Left wing: Drilled outboard flap arms: #40, #14, then reamed to 3/16. Reinstalled tube and arms in wing. Used Dremel with brass brush to remove paint from aux pump mounting points and applied OxGard to provide ground connection for pump.

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Feb 24, 2024 Pitot mast mount - (2 hours)

Category: Wings

Pitot mast mount: used 5 wraps of vinyl tape to establish perimeter of mast opening for final sanding. Sanded with 120 grit with doubler in place. Deburred skin and doubler. Sanded doubled 320 and 600 grit and primed with Duplicolor Self etching primer.

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Feb 11, 2024 Pitot mount - (3 hours)

Category: Wings

Pitot tube mount: trimmed and sanded edges of doubler. Assembled doubler and mast to wing and used several layers of vinyl tape to help mark a setback line on wing skin around mast.

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Feb 10, 2024 Left wing inspection plates - (1 hour)

Category: Wings

Left wing inspection plates: sanded 4L and 5L to fit openings.

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Feb 09, 2024 Left wing inspection plates - (1 hour)

Category: Wings

Left wing inspection plates: 2L and 3L final sanding to fit.

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Feb 07, 2024 Left wing inspection plates - (1 hour)

Category: Wings

Left wing inspection plates: 1L final sand to fit.

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Feb 04, 2024 Left wing inspection plates and pitot mount - (4 hours)

Category: Wings

Left wing inspection plates and pitot mount: riveted nut plates to pitot mast. Dimpled 3/32” rivet holes in wing skin for doubler plate using pop rivet dimpling tool. Riveted all 5 inspection plate rings into place.

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Feb 04, 2024 Pitot mount - (4 hours)

Category: Wings

Pitot mount: match drilled mast baseplate to doubler and wing skin with #27 bit. Used #27 bits wrapped in vinyl tape to keep parts aligned while up drilling. Deburred and dimpled doubler. Drilled mast baseplate for nut plates, and deburred and countersunk as needed.

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Feb 02, 2024 Pitot mount - (3 hours)

Category: Wings

Pitot mount: cut and deburred hole in skin and doubler for mast. Drilled #40 locating holes for nut plates in mast base.

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Feb 01, 2024 Pitot mount - (1 hour)

Category: Wings

Pitot mast install: rethinking nut plate locations to avoid any impact on spar cap. Finished match drilling doubler to skin. Marked outline of mast opening in skin.

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Jan 31, 2024 Pitot mount - (1 hour)

Category: Wings

Pitot mount: match drilled doubler plate to spar cap and rib. Mapped out rivet locations for joining doubler to skin. Mocked up conceptual nut plate locations.

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Jan 30, 2024 Pitot tube mount - (1 hour)

Category: Wings

Pitot tube mount: finished sanding edges of doubler plate. Finalized doubler location and got one hole match drilled to rib.

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Jan 29, 2024 Pitot tube mount - (1 hour)

Category: Wings

Pitot tube mount: drilled out four spar and rib rivets. Started trimming doubler plate to fit.

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Jan 28, 2024 Pitot tube mount - (4 hours)

Category: Wings

Pitot tube mount: after some experimenting, made a joggle fixture from .050” 2024-T3. Slot width .200”. Used this tool and bench vice to form joggles on .032 2024-T3 5” square sheet to overlap rib flange and spar cap.

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Jan 27, 2024 Left wing inspection plates and pitot mast - (3 hours)

Category: Wings

Left wing: inspection plate rings: stripped outer side with acetone, sanded with scotchbrite, and primed 3 coats RO self etching primer. Mocked up aileron cable to ensure clearance from pitot mast. Started working on doubler for mast mount. Made a prototype joggle tool from .032 2023 T6. Need to use thicker material and wider slot.

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Jan 26, 2024 Pitot mount research - (1 hour)

Category: Wings

Pitot tube mounting research: visited Murlin Lee's RV9A build and took a bunch of pictures.

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Jan 25, 2024 Left wing inspection plates - (1 hour)

Category: Wings

Left wing inspection plates: 4L and 5L: deburred and dimpled ring rivet holes.

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Jan 24, 2024 Left wing inspection plates - (1 hour)

Category: Wings

Left wing inspection plates: 4L and 5L: match drilled rings to wing skin.

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Jan 23, 2024 Left wing inspection plates - (2 hours)

Category: Wings

Left wing inspection plates: 2L: dimpled skin and ring at attach rivet locations. 4L, 5L: mounted nut plates to rings. Marked skin at ring attach rivet locations.

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Jan 21, 2024 Left wing inspection plates - (4 hours)

Category: Wings

Left wing inspection plates: Match drilled rings 3L and 2L to skin. Dimpled ring and skin at location 3L.

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Jan 20, 2024 Left wing inspection plates - (2 hours)

Category: Wings

Left wing inspection plates: 3L: installed nut plates to ring.
Dimpled all plates.

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Jan 19, 2024 Left wing inspection plates - (3 hours)

Category: Wings

Left wing inspection plates:
1L: match drilled to wing skin. Deburred and dimpled holes.
2L: installed nut plates to ring.
3,4,5L: dimpled rivet holes on rings at nut plate locations.

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Jan 18, 2024 Left wing inspection plates - (1 hour)

Category: Wings

Left wing inspection plates: dimpled ring 1L and nut plates. Riveted nut plates to ring.

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Jan 17, 2024 Left wing inspection plates - (1 hour)

Category: Wings

Left wing inspection plates: countersunk all screw locations on rings. Started marking rivet locations on wing skins.

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Jan 16, 2024 Left wing inspection plates - (2 hours)

Category: Wings

Left wing inspection plates: deburred rings and plates. Started countersinking rings.

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Jan 15, 2024 Left wing inspection plates - (1 hour)

Category: Wings

Left wing inspection plates: match drilled plate and ring 5L. Started deburring all plates and rings.

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Jan 11, 2024 Left wing inspection plates - (1 hour)

Category: Wings

Left wing inspection plates: drilled plate and ring 4L.

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Jan 10, 2024 Left wing inspection plates - (1 hour)

Category: Wings

Left inspection plates: plate 2L match drilled to ring. Drilled ring for nut plates.

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Jan 09, 2024 Left wing inspection plates - (2 hours)

Category: Wings

Left wing inspection covers: match drilled two covers to rings and drilled rings for nut plates.

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Jan 08, 2024 Left wing inspection plates - (1 hour)

Category: Wings

Left wing inspection plates: matched up rings and plates. Serialized all. Measured and marked screw locations on all plates.

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Jan 07, 2024 Left wing inspection plates - (4 hours)

Category: Wings

Left wing inspection plates: finished up fabrication of replacement aileron bellcrank access cover.

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Jan 06, 2024 Left wing inspection plates - (4 hours)

Category: Wings

Left wing inspection plates: installed missing nut plates at aileron bellcrank port. Sorted and marked other plates and rings. Started match marking and drilling replacement aileron bellcrank cover.

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Jan 05, 2024 Left wing inspection plates - (2 hours)

Category: Wings

Left wing inspection plates: decided to make a replacement plate for the aileron bellcrank opening to resolve issue with misaligned nut plates. Cut blank to size and rounded corners.

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Jan 04, 2024 Left wing aux tank cover and inspection plates - (2 hours)

Category: Wings

Left wing: completed drill and deburr of aux tank drain hole in cover. Tried to install aileron bellcrank cover. Many holes don't line up properly. Factory workmanship issue - it seems the match-drilling was accurate, but several nut plates ended up not centered on the holes in the inspection ring and rib. I did double-confirm that I don't have the covers swapped between left and right wings! Will need to make a new cover.

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Jan 03, 2024 Left aux tank cover - (1 hour)

Category: Wings

Left aux tank cover: reinstalled straps and tank. Marked quick drain location and drilled Pilot hole.

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Jan 02, 2024 Pitot Mast: Installation Planning - (2 hours)

Category: Wings

Goal:
Find a spot for the Aircraft Spruce Pitot Mast (Avery SA-06BL) that meets Dynon and Garmin G3X installation requirements. See attached MSWord doc and photos for details and plan

Pitot Mast Install.docx

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Dec 20, 2023 Left Aux Tank Cover - (2 hours)

Category: Wings

Edge rolled and dimpled cover.

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Dec 19, 2023 Left aux tank cover - (2 hours)

Category: Wings

Left aux tank cover: set the last 7 rivets using rivet gun. Rounded corners of cover with Vixen file and sandpaper. Deburred holes and edges of cover.

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Dec 18, 2023 Left aux tank cover - (1 hour)

Category: Wings

Left aux tank cover: used pneumatic squeezer to set almost all rivets on nut plates. 7 left which will require gun and bucking bar.

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Dec 17, 2023 Left wing aux tank cover and pitot - (1 hour)

Category: Wings

Left wing: finished placing rivets for aux tank cover nut plates. Stripped plastic from aux tank cover. Took pictures of pitot tube installation on C182S for research purposes. Purchased pitot mast SA-06BL from Aircraft Spruce.

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Dec 16, 2023 Left aux tank cover - (1 hour)

Category: Wings

Left aux tank cover: riveted nut plates along aft edge of opening. Placed and taped rivets along inboard edge.

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Dec 15, 2023 Left aux tank cover - (2 hours)

Category: Wings

Left aux tank cover: placed all nut plates and secured with #6x1/4 screws.

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Dec 14, 2023 Left aux tank cover - (2 hours)

Category: Wings

Left aux tank cover: pulled masking off primed areas on bay edges. Placed and riveted nut plates along front edge. Placed nut plates along inboard edge.

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Dec 13, 2023 Left aux tank cover - (2 hours)

Category: Wings

Left aux tank cover: finished masking and primed nut plate areas around opening with Rustoleum self etching primer. Also primed shims for corner nut plates.

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